Operation Manual, Model KCT/KCP ATS (TP

Operation and

Installation

Automatic Transfer Switches

Models:

KCT, KCP

Power Switching Device:

Standard

Open-Transition 30 to 4000 Amps

Programmed-Transition 150 to 4000 Amps

Electrical Controls:

MPAC 1000 t

TP-6126 8/02b

Product Identification Information

Product identification numbers determine service parts.

Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.

Record field-installed kit numbers after installing the kits.

Transfer Switch Identification Numbers

Record the product identification numbers from the transfer switch nameplate.

Model Designation

Serial Number

Accessory Number Accessory Description

x:in:007:001

Table of Contents

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inside front cover

Safety Precautions and Instructions

Service Assistance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Receipt of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.3

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.4

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Manual Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1

Manual Operation, 30--200 Amp Open-Transition Switches . . . . . . . . . .

2.4.2

Manual Operation, 225--4000 Amp Open-Transition Switches . . . . . . .

2.4.3

Manual Operation, Programmed-Transition Switches . . . . . . . . . . . . . . .

2.5

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.1

AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2

Engine Start Connection

2.5.3

Auxiliary Contacts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.4

Controller Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

9

10

13

15

16

5

5

6

4

4

4

3

3

3

3

3

1

1

1

2 i i

I ii

Section 3 Setup and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

User Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1

Pushbuttons and LED Indicators

3.2.2

Controller Reset

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Controller Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1

Main Logic Board DIP Switch Settings

3.3.2

Main Logic Board Inputs and Outputs

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3

Communications Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Programmed-Transition Interface Board (PTIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

System Settings and Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1

System Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.2

Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6

Generator Set Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7

Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.1

Manual Operation Test

3.7.2

Voltage Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.3

Automatic Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

Exerciser Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9

Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

22

22

23

23

23

23

23

25

26

26

17

17

17

17

18

19

20

20

21

Section 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1

Automatic Operation, Open- and Programmed-Transition Switches . . .

4.2.2

System Test

4.2.3

Exerciser

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

27

27

27

29

31

TP-6126 8/02 Table of Contents

Table of Contents, continued

4.2.4

Peak Shave/Area Protection Operation Sequence

4.2.5

Pre- and Post-Transfer Load Control Sequence

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

4.3

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1

Service Required LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2

Auxiliary Switch Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3

Failure to Acquire Standby Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.4

Failure to Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.5

Phase Rotation Faults

4.4

Controller Power Supply

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

35

36

36

36

36

36

36

36

Section 5 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1

Weekly Generator Set Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2

Monthly Automatic Control System Test . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1

General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2

Other Inspections and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4

Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

37

38

38

38

38

38

39

40

Section 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2

Setup Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1

Preferred Source Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.2

Supervised Transfer Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

In-Phase Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5

Programmable Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5.1

Programmable Input/Output (I/O) Modules . . . . . . . . . . . . . . . . . . . . . . . .

6.5.2

I/O Module Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5.3

I/O Module Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5.4

I/O Module Faults and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Load Shed (Forced Transfer to OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.1

Description

6.6.2

Connection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Security Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8.1

Battery Charger Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8.2

Battery Charger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8.3

Battery Charger Troubleshooting

6.8.4

Battery Charger Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

41

41

41

41

44

45

45

46

47

48

48

50

51

54

55

56

49

49

49

49

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-57

Appendix B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-60

Table of Contents TP-6126 8/02

IMPORTANT SAFETY

INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.

Read and follow all safety precautions and instructions.

SAVE

THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions: Danger,

Warning, Caution, and Notice.

Safety Precautions and Instructions

Battery

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.

The decals are shown throughout this publication to improve operator recognition.

Replace missing or damaged decals.

Accidental Starting

WARNING

WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.

Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

WARNING

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Accidental starting.


Disconnect the battery cables before working on the generator set.

Remove the negative (--) lead first when disconnecting the battery.

Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Explosion.


Relays in the battery charger cause arcs or sparks.

Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.

TP-6126 8/02 Safety Precautions and Instructions I

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.

Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.

Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.

Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.

Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.

Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits.

Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage.

Disconnect the battery before generator set installation or maintenance.

Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Hazardous Voltage/

Electrical Shock

DANGER

Hazardous voltage.

Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

DANGER

Hazardous voltage.


Disconnect all power sources before servicing.

Install the barrier after adjustments, maintenance, or servicing.

DANGER

Hazardous voltage.


Only authorized personnel should open the enclosure.

WARNING

Hazardous voltage.

Moving rotor.


Operate the generator set only when all guards and electrical enclosures are in place.

Grounding electrical equipment.

Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.

Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards.

Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

II Safety Precautions and Instructions TP-6126 8/02

Installing the battery charger.

Hazardous voltage can cause severe injury or death.

An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances.

Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.

Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).

Have a qualified electrician install the battery(ies).

Short circuits.

Hazardous voltage/current can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage.

Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

Remove all jewelry before servicing the equipment.

Installing accessories to the transformer assembly. Hazardous voltage can cause severe injury or death.

To prevent electrical shock disconnect the harness plug before installing accessories that will be connected to the transformer assembly primary terminals on microprocessor logic models.

Terminals are at line voltage.

Making line or auxiliary connections.

Hazardous voltage can cause severe injury or death. To prevent electrical shock deenergize the normal power source before making any line or auxiliary connections.

Servicing the transfer switch.

Hazardous voltage can cause severe injury or death. Deenergize all power sources before servicing. Open the main circuit breakers of all transfer switch power sources and disable all generator sets as follows: (1) Move all generator set master controller switches to the OFF position.

(2)

Disconnect power to all battery chargers.

(3) Disconnect all battery cables, negative (--) leads first.

Reconnect negative (--) leads last when reconnecting the battery cables after servicing. Follow these precautions to prevent the starting of generator sets by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Before servicing any components inside the enclosure: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat.

(3) Test circuits with a voltmeter to verify that they are deenergized.

Servicing the transfer switch controls and accessories within the enclosure. Hazardous voltage can cause severe injury or death.

Disconnect the transfer switch controls at the inline connector to deenergize the circuit boards and logic circuitry but allow the transfer switch to continue to supply power to the load. Disconnect all power sources to accessories that are mounted within the enclosure but are not wired through the controls and deenergized by inline connector separation.

Test circuits with a voltmeter to verify that they are deenergized before servicing.

Testing live electrical circuits.

Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits.

Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry.

(2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure.

(4) Be prepared for the system to operate automatically.

(600 volts and under)

Heavy Equipment

WARNING

Unbalanced weight.

Improper lifting can cause severe injury or death and equipment damage.

Use adequate lifting capacity.

Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized.

TP-6126 8/02 Safety Precautions and Instructions III

Moving Parts

WARNING

Hazardous voltage.

Moving rotor.



WARNING

Airborne particles.

Can cause severe injury or blindness.

Wear protective goggles and clothing when using power tools, hand tools, or compressed air.

Notice

NOTICE

Hardware damage.

The transfer switch may use both American

Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware.

Screws and nuts are available in different hardness ratings.

To indicate hardness, American

Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE

Improper operator handle usage.

Use the manual operator handle on the transfer switch for maintenance purposes only.

Return the transfer switch to the normal position. Remove the manual operator handle, if used, and store it in the place provided on the transfer switch when service is completed.

NOTICE

Foreign material contamination.

Cover the transfer switch during installation to keep dirt, grit, metal drill chips, and other debris out of the components.

Cover the solenoid mechanism during installation. After installation, use the manual operating handle to cycle the contactor to verify that it operates freely. Do not use a screwdriver to force the contactor mechanism.

NOTICE

Electrostatic discharge damage.

Electrostatic discharge (ESD) damages electronic circuit boards.

Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about

1 megohm), not a direct short, to ground.

IV Safety Precautions and Instructions TP-6126 8/02

This manual provides operation and installation instructions for Kohler r Model KCT/KCP automatic transfer switches with MPAC 1000 t electrical controls.

t:in:002:001a

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this literature and the products represented without notice and without any obligation or liability whatsoever.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the

Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect parts often and perform required service at the prescribed intervals.

Obtain service from an authorized service distributor/dealer to keep equipment in top condition.

x:in:002:002

Introduction

List of Related Materials

This manual includes operation and installation information for standard open-transition and programmed-transition transfer switches. Decode the transfer switch model number from the transfer switch nameplate and verify that the it matches the model shown on the front cover of this manual before proceeding with installation.

Separate manuals cover service and parts information.

The following table lists the related literature part numbers.

Literature Item

Specification Sheet

Service Manual

Parts Catalog

MPAC t Setup Program Operation Manual

Part Number

G11-80

TP-6127

TP-6158

TP-6135

TP-6126 8/02 Introduction i

Service Assistance

For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D

Consult the Yellow Pages under the heading

Generators—Electric

D

Visit the Kohler Power Systems website at

KohlerPowerSystems.com

D

Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product

D

Call toll free in the US and Canada 1-800-544-2444

D

Outside the US and Canada, call the nearest regional office

Africa, Europe, Middle East

London Regional Office

Langley, Slough, England

Phone: (44) 1753-580-771

Fax: (44) 1753-580-036

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 264-6422

Fax: (65) 264-6455

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131

X:in:008:001a ii Service Assistance TP-6126 8/02

Section 1 Product Description

1.1 Purpose

An automatic transfer switch (ATS) transfers electrical loads from a normal (preferred) source of electrical power to an emergency (standby) source when the normal source falls outside the acceptable electrical parameters.

When the normal (preferred) source fails, the ATS signals the emergency (standby) source generator set to start. When the emergency (standby) source reaches acceptable levels and stabilizes, the ATS transfers the load from the normal (preferred) source to the emergency (standby) source. The ATS continuously monitors the normal (preferred) source and transfers the load back when the normal (preferred) source returns and stabilizes. After transferring the load back to the normal (preferred) source, the ATS removes the generator start signal, allowing the generator set to shut down.

Figure 1-1 shows a typical installation block diagram.

1.2 Nameplate

A nameplate attached to the controller cover on the inside of the enclosure door includes a model designation, a serial number, ratings, and other information about the transfer switch. See Figure 1-2.

Copy the model designation, serial number, and accessory information from the nameplate to the spaces provided in the Product Identification Information section inside the front cover of this manual for use when requesting service or parts.

Copy the model designation into the spaces in Section 1.3 and use the accompanying chart to interpret the model designation.

The serial number is also shown on a label inside the transfer switch enclosure.

Power

Switching

Device

Normal

(Utility)

Power

Emergency

(Generator)

Power

Generator

Start Generator

Electrical

Controls

Automatic Transfer Switch

To Load

Figure 1-1 Typical ATS Block Diagram

1

2

TS-003

3

1. Model designation

2. Serial number

3. Factory-installed accessory numbers

Figure 1-2 Typical Transfer Switch Nameplate

GM21291

TP-6126 8/02 Section 1 Product Description 1

1.3 Model Code

Record the transfer switch model designation in the boxes below. The transfer switch model designation defines characteristics and ratings as explained in the accompanying chart.

Model Mechanism Transition Controls Voltage Poles Enclosure Current Rating Connections

Kohler rrrr Model Designation Key

This chart explains the Kohler r transfer switch model designation system. The sample model designation shown is for a Model K automatic transfer switch that uses an open-transition contactor with MPAC 1000 t electrical controls rated at 480 volts/60 Hz,

3 poles, 4 wires, and solid neutral in a NEMA 1 enclosure with a current rating of

225 amperes. Not all possible combinations are available.

Model

K: Model K automatic transfer switch

Mechanism

C: Automatic

B: Bypass Isolation (See G11-81)

N: Non-automatic

Transition

T: Open-Transition

P: Programmed-Transition

Electrical Controls

A: MPAC 1000 t (Microprocessor ATS Controls)

Voltage/Frequency

C: 208 Volts/60 Hz

D: 220 Volts/50 Hz

F: 240 Volts/60 Hz

G:

H:

J:

380 Volts/50 Hz

400 Volts/50 Hz

416 Volts/50 Hz

Number of Poles/Wires

N: 2-pole, 3-wire, solid neutral

T: 3-pole, 4-wire, solid neutral

V: 4-pole, 4-wire, switched neutral

K:

M:

N:

440 Volts/60 Hz

480 Volts/60 Hz

600 Volts/60 Hz

W: 4-pole, 4-wire, overlapping neutral

Z: 3-pole, 4-wire, integral solid neutral*

Enclosure

A: NEMA 1

[

B: NEMA 12

]

C: NEMA 3R

]

D: NEMA 4

]

F: NEMA 4X

G: Open unit

]

[ Standard on 30--4000 A models

] Available to order on 30--800 A models. For larger units, consult the factory.

Current Rating: Numbers indicate the current rating of the switch in amperes:

0030

0070

0104

0150

0200

0225

0260

0400

0600

0800

1000

1200

1600

2000

2600

3000

4000

Power Connections

S: Standard

F: Front bus (available on 1600 and 2000 A models only)

* Integral solid neutral is a solid neutral mounted on the contactor.

(Not available on all amperages.)

SAMPLE MODEL DESIGNATION

KCT-AMTA-0225S

2 Section 1 Product Description TP-6126 8/02

2.1 Introduction

Kohler r transfer switches are shipped factory-wired, factory-tested, and ready for installation.

Have the equipment installed only by trained and qualified personnel, and verify that the installation complies with applicable codes and standards.

Switch installation includes the following steps:

D

Unpacking and inspecting the transfer switch upon receipt.

D

Verifying that the transfer switch voltage and frequency ratings match the voltages and frequencies of the sources.

D

Mounting the transfer switch.

D

Checking the manual operation.

D

Wiring the normal power source (utility), emergency power source (generator set), and load circuits.

D

Wiring the generator set engine start connection.

D

Connecting accessories, if provided.

D

Connecting and initializing the electrical controls, as required.

D

Checking voltages and operation.

Protect the switch against damage before and during installation.

The functional tests in Section 3.7 are a necessary part of the installation. Be sure to perform the functional tests, which include voltage checks and operation tests, before putting the transfer switch into service.

2.2 Receipt of Unit

2.2.1

Inspection

At the time of delivery, inspect the packaging and the transfer switch for signs of shipping damage. Unpack the transfer switch as soon as possible and inspect the exterior and interior for shipping damage. If damage and/or rough handling is evident, immediately file a damage claim with the transportation company.

2.2.2

Lifting

Section 2 Installation

WARNING

Unbalanced weight.

Improper lifting can cause severe injury or death and equipment damage.

Use adequate lifting capacity.

Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized.

See Figure 2-1 through Figure 2-4 or the dimensional drawing for the weight of the transfer switch. Use a spreader bar to lift the transfer switch. Attach the bar only to the enclosure’s mounting holes or lifting brackets; do not lift the unit any other way. Close and latch the enclosure door before moving the unit.

Amps

30--200

225--400

600--800

1000--1200

1600--2000

2600--3000

4000

2-Pole

28 (62)

52 (115)

220 (485)

—

—

—

—

Weight, kg (lb.)

3-Pole

30 (65)

56 (123)

231 (510)

356 (785)

472 (1040)

649 (1430)

1043 (2300)

4-Pole

31 (68)

59 (131)

238 (525)

379 (835)

494 (1090)

679 (1495)

1089 (2400)

Figure 2-1 Weights, Open-Transition Models in

NEMA 1 Enclosures

Amps

150--400

600--800

1000--1200

1600--2000

2600--3000

4000

2-Pole

179 (395)

179 (395)

—

—

—

—

Weight kg, (lb.)

3-Pole

183 (403)

184 (405)

463 (1020)

533 (1175)

735 (1620)

1115 (2457)

4-Pole

187 (413)

188 (415)

485 (1070)

556 (1225)

765 (1685)

1160 (2557)

Figure 2-2 Weights, Programmed-Transition Models in NEMA 1 Enclosures

TP-6126 8/02 Section 2 Installation 3

Amps

30--200

225--400

600--1200

1600--2000

2600--3000

4000

2-Pole

8 (17)

17 (37)

68 (150)

—

—

—

Weight kg (lb.)

3-Pole

9 (20)

21 (45)

78 (170)

190 (420)

213 (470)

545(1200)

4-Pole

11 (23)

24 (53)

90 (196)

213 (470)

243 (535)

590(1300)

Figure 2-3 Weights, Open Units, Open-Transition

Models

Amps

150--400

600--1200

1600--2000

2600--3000

4000

2-Pole

21 (45)

80 (175)

—

—

—

Weight kg (lb.)

3-Pole

24 (53)

94 (205)

252 (555)

300 (660)

611(1347)

Figure 2-4 Weights, Open Units,

Programmed-Transition Models

4-Pole

28 (63)

108 (235)

274 (605)

329 (725)

657(1447)

2.2.3

Storage

Store the transfer switch in its protective packing until final installation. Protect the transfer switch at all times from moisture, construction grit, and metal chips. Avoid storage in low-temperature and high-humidity areas where moisture could condense on the unit.

See

Figure 2-5 for acceptable storage temperatures.

Item

Storage

Temperature

Operating

Temperature

Humidity

Altitude

Specification

--40

°C to 70°C (--40°F to 158°F)

--20

°C to 70°C (--4°F to 158°F)

5% to 95% noncondensing

0 to 3050 m (10000 ft.) without derating

Figure 2-5 Environmental Specifications

2.2.4

Unpacking

Allow the equipment to warm to room temperature for at least 24 hours before unpacking to prevent condensation on the electrical apparatus. Use care when unpacking to avoid damaging transfer switch components. Remove dirt and packing material that may have accumulated in the transfer switch or any of its components. Do not use compressed air to clean the switch. Cleaning with compressed air can cause debris to lodge in the components and damage the switch.

4 Section 2 Installation

For 600--800 amp transfer switches, remove the lag screws that secure the transfer switch to the shipping skid. For 1000--4000 amp transfer switches, open the enclosure door to remove the lag screws that secure the transfer switch to the skid.

2.3 Mechanical Installation

NOTICE

Foreign material contamination. Cover the transfer switch during installation to keep dirt, grit, metal drill chips, and other debris out of the components. Cover the solenoid mechanism during installation. After installation, use the manual operating handle to cycle the contactor to verify that it operates freely.

Do not use a screwdriver to force the contactor mechanism.

NOTICE

Hardware damage.

The transfer switch may use both

American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

Check the system voltage and frequency. Compare the voltage and frequency shown on the transfer switch nameplate to the source voltage and frequency. Do not install the transfer switch if the system voltage and frequency are different from the nominal normal (utility) source voltage and frequency or the nominal emergency source voltage and frequency shown on the generator set nameplate.

Plan the installation. Use the dimensions given on the enclosure dimension (ADV) drawings.

Select a mounting site that complies with local electrical code restrictions for the enclosure type. Mount the transfer switch as close to the load and power sources as possible.

Allow adequate space to fully open the enclosure and to service the switch.

Provide cable bending space and clearance to live metal parts.

Prepare the foundation. Ensure that the supporting foundation for the enclosure is level and straight. For bottom cable entry, if used, install conduit stubs in the foundation. Refer to the enclosure dimension drawing for the conduit stub locations. When pouring a concrete floor, use interlocking conduit spacer caps or a wood or metal template to maintain proper conduit alignment.

Install the ATS. For easy access during installation and wiring, remove the front door of the enclosure. For

30--200 amp switches, support the door and remove the two screws at the bottom. Slide the door down until the top clears the enclosure. Open the door wide enough to reach the controller wiring on the inside of the door.

Disconnect the cable plug that connects the front door components to the internal components and disconnect the grounding wire between the door and the enclosure.

Set the door out of the way to protect the controls.

TP-6126 8/02

For units with hinged doors, open the door and disconnect the cable plug that connects the front door components to the internal components. Disconnect the grounding wire between the door and the enclosure.

Squeeze the release pins on each hinge together and remove the door. See Figure 2-6. Set the door out of the way to protect the controls.

Vertically mount 30- through 400-amp transfer switches to a wall or other rigid vertical supporting structure. Use the template on the shipping carton to locate the mounting holes in the wall. Level the template before marking and drilling the holes. Clearance holes through the back of each enclosure are provided for mounting.

Use shims to plumb the enclosure. Verify that the door hinges are vertical to avoid distortion of the enclosure or door.

Bolt 600through 4000-amp automatic transfer switches directly to floor mounting pads. Shim the enclosure so that the enclosure is plumb.

2.4 Manual Operation Check

DANGER

Hazardous voltage.



Note: A manual operation handle is provided on the transfer switch for maintenance purposes only. Do not use the manual operation handle to transfer the load with the power connected.

Use the manual operation handle to check the manual operation before energizing the transfer switch.

On programmed-transition models, check the operation of both the Normal and Emergency operators. Use the following manual operation procedures to verify that the contactor operates smoothly without binding.

Note: A contactor in normal and serviceable condition operates smoothly without binding. Do not place the transfer switch into service if the contactor does not operate smoothly; contact an authorized distributor/dealer to service the contactor.

1

1. Hinge release pins

Figure 2-6 Hinge

Manual Operation Test Procedure, 30--200 Amp

Transfer Switches

6126

2.4.1

Manual Operation, 30--200 Amp

Open-Transition Switches

The 30--200 amp open-transition models have an attached manual operating handle. See Figure 2-7.

1. Turn the attached handle to manually operate the transfer switch. It should operate smoothly without any binding. If it does not, check for shipping damage or construction debris.

2. Return the transfer switch to the Normal position.

1

127a

1. Handle

Figure 2-7 Manual Operation Handle, 30--200 Amp



2.4.2

Manual Operation, 225--4000 Amp


DANGER

Hazardous voltage.



The 225--4000 amp open-transition models use a detachable manual operating handle.

NOTICE

Improper operator handle usage. Use the manual operator handle on the transfer switch for maintenance purposes only.



Open-Transition Transfer Switches

1. Remove the maintenance handle from the clips on the left side of the transfer switch frame.

See

Figure 2-8.

2. 225--400 amp switches: See Figure 2-9. Insert the maintenance handle into the hole in the shaft on the left side of the operator.

600--1200 amp switches: See Figure 2-10.

Insert the maintenance handle into the hole in the molded hub on the left side of the operator.

1600--2000 amp switches: See Figure 2-11.

Slide the hub onto the shaft and insert the maintenance handle into the hole in the hub.

3000 and 4000 amp switches: See Figure 2-12.

Insert the maintenance handle into the hole in the weight.

3. Move the maintenance handle up or down as shown to manually operate the transfer switch. It should operate smoothly without any binding. If it does not, check for shipping damage or construction debris.

4. Return the transfer switch to the Normal position.

5. Remove the maintenance handle and store it on the frame in the clips provided.

2

1

1. Maintenance handle

2. Storage clips

202

Figure 2-8 Manual Handle Storage, 600--1200 Amp

Switch Shown

6 Section 2 Installation TP-6126 8/02

1

1

2

127a


2. Shaft

Figure 2-9 Manual Operation, 225--400 Amp

Open-Transiton Switches and 150--400

Amp Programmed-Transition Switches

(one operator shown)

2

Turn counterclockwise to Emergency.

Turn clockwise to Normal.


2. Hub


Switches

127a

2

1

2

127a


2. Hub


Switches

202

1. Weight


Figure 2-12 Manual Operation, 4000 amp switches


2.4.3

Manual Operation,

Programmed-Transition Switches

Programmed-transition switches have two operators,

Normal and Emergency, on the left side of the contactor assembly. Mechanical interlocks prevent closing both operators at the same time. Refer to Figure 2-13 for typical locations of the Normal and Emergency operators.

Position indicators on the right side of the contactor assembly show the positions of the operators. See

Figure 2-14.

Programmed-transition models use a detachable manual operating handle. Refer to Figure 2-8 through

Figure 2-12.

DANGER

Emergency Operator

(shown open)

Hazardous voltage.



NOTICE

Improper operator handle usage. Use the manual operator handle on the transfer switch for maintenance purposes only.



Programmed-Transition Transfer Switches

Check the operation of both operators by following the instructions in Section 2.4.2 for both the Normal and

Emergency operators in the following sequence:

1. Starting with the contactor in the Normal position, use the maintenance handle to move the Normal operator from the closed to the open position. See

Figure 2-13 and Figure 2-14.

2. Move the Emergency operator from the open position to the closed position.

3. Return the Emergency operator to the open position and the Normal operator to the closed position.

4. Remove the maintenance handle and store it in the place provided on the switch.

Normal Operator

(shown closed)

Figure 2-13 Programmed-Transition Switch Normal and Emergency Operators, 600--1200

Amp Model (shown in Normal position)

1

2

1. Emergency contact indicator: O is Open, C is closed

2. Normal contact indicator

202

Figure 2-14 Contact Position Indicators (located on the right side of the contactor assembly, shown in Normal position)


2.5 Electrical Wiring

All internal electrical connections are factory-wired and tested.

Field installation includes connecting the sources, loads, generator start circuit(s), and auxiliary circuits, if used.

Note: Do not connect the wiring harness to the controller until instructed to do so in the voltage check procedure, Section 3.7.2.

Refer to the wiring diagrams provided with the transfer switch. Observe all applicable national, state, and local electrical codes during installation.

Install DC, control, and communication system wiring in metal conduit separate from AC power wiring.

It is not necessary to remove pole covers from the transfer switch for cabling. If you do remove them, reinstall them carefully.

WARNING

DANGER

Hazardous voltage.



DANGER








Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the

OFF position. (2) Disconnect the power to the battery charger.

(3) Remove the battery cables, negative (--) lead first.


Hazardous voltage.




Making line or auxiliary connections. Hazardous voltage can cause severe injury or death. To prevent electrical shock deenergize the normal power source before making any line or auxiliary connections.

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.

Open the main circuit breakers of all power sources before servicing the equipment.

Configure the installation to electrically ground the generator set and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

NOTICE

Electrostatic discharge damage. Electrostatic discharge

(ESD) damages electronic circuit boards.

Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short, to ground.


2.5.1

AC Power Connections

Determine the cable size.

Refer to the table in

Figure 2-15 to determine the cable size and number of cables required for the transfer switch. Make sure the lugs provided are suitable for use with the cables being installed. Watertight conduit hubs may be required for outdoor use.

Note: Use only copper wire for 200 amp models.

UL-Listed Solderless Screw-Type Terminals for External Power Connections

Normal, Emergency, and Load Terminals

Switch

Rating

(Amps)

30, 70, 104

150

200

600

800--1200

1600--2000

2600--3000

Maximum Number of

Cables per Pole

1

1

1

1

4

6

2

3

12

4000

Figure 2-15 Cable Sizes

Range of Wire Sizes,

Copper or Aluminum

#14 AWG to 2/0 AWG

#8 AWG to 3/0 AWG

#8 AWG to 3/0 AWG

(use copper wire only)

#4 AWG to 600 MCM

#1/0 AWG to 250 MCM

#2 AWG to 600 MCM

#1/0 AWG to 750 MCM

#1/0 AWG to 750 MCM

#1/0 AWG to 750 MCM

Bus Bar

NOTICE

Foreign material contamination. Cover the transfer switch during installation to keep dirt, grit, metal drill chips, and other debris out of the components. Cover the solenoid mechanism during installation. After installation, use the manual operating handle to cycle the contactor to verify that it operates freely.

Do not use a screwdriver to force the contactor mechanism.

Drill the entry holes.

Cover the transfer switch to protect it from metal chips and construction grit. Then drill entry holes for the conductors at the locations shown on the enclosure drawings. Remove debris from the enclosure with a vacuum cleaner.

Do not use compressed air to clean the switch because it can cause debris to lodge in the components and cause damage.

Install and test the power cables. Leave sufficient slack in the power leads to reach all of the power connecting lugs on the power switching device. Test the power conductors before connecting them to the transfer switch. Installing power cables in conduit, cable troughs and ceiling-suspended hangers often requires considerable force.

Pulling cables can damage insulation and stretch or break the conductor’s strands.


Test the cables after pulling them into position and before they are connected to verify that they are not defective and that they were not damaged during installation.

Install the cable spacers provided with 30--200 amp switches as shown in Figure 2-16. On 225--400 amp switches, verify that the factory-installed insulator backing piece shown in Figure 2-17 is in place behind the contactor.

1

1 ½ inch approximate

1

127

1. Cable spacers

Figure 2-16 Cable Spacers for 30--200 Amp Switches

1

1. Insulator backing piece

2. Contactor

Figure 2-17 Insulator for 225--400 Amp Switches

127

TP-6126 8/02

Connect the cables.

Be careful when stripping insulation from the cables; avoid nicking or ringing the conductor. Clean cables with a wire brush to remove surface oxides before connecting them to the terminals.

Apply joint compound to the connections of any aluminum conductors.

Refer to Figure 2-20, Interconnection Diagram, and the wiring diagram provided with the switch. A list of the drawing numbers for the wiring diagrams and schematics is given in Appendix B.

The connection points on the contactor are labeled

Normal, Emergency, and Load. Be sure to follow the phase markings (A, B, C, and N). For single-phase systems, connect to A and C.

Note: Connect the source and load phases as indicated by the markings and drawings to prevent short circuits and to prevent phase-sensitive load devices from malfunctioning or operating in reverse.

On models equipped with the optional preferred source switch, connect source N to the normal side and source

E to the emergency side of the contactor.

Verify that all connections are consistent with drawings before tightening the lugs.

Tighten all cable lug connections to the torque values shown on the label on the switch. (See Figure 2-19 for a typical rating/torque label.) Carefully wipe off any excess joint compound after tightening the terminal lugs.

For load connections to bus bars, use a compression washer, flat washer, and a minimum grade 5 bolt and torque the connections to the values in Figure 2-18.

inches

1/4

5/16

3/8

1/2

5/8

3/4

Bolt Torque ft. lbs.

7

12

20

50

95

155

Nm

9.5

16.3

27.1

67.8

128.8

210.2

Figure 2-18 Tightening torque for bus bars

SUITABLE FOR CONTROL OF MOTORS, ELEC

DISCHARGE AND TUNGSTEN LAMPS, ELEC HEAT--

ING EQPT, WHERE THE SUM OF MOTOR FULL--

LOAD AMPS AND AMPS OF OTHER LOADS DOES

NOT EXCEED THE SWITCH AMP RATING AND THE

100 % OF TUNGSTEN LOAD DOES NOT EXCEED

SWITCH RATING, 240V MAX.

WHEN PROTECTED BY A CIRCUIT BREAKER

WITHOUT AN ADJUSTABLE SHORT--TIME RESPONSE

ONLY OR BY FUSES THIS TRANSFER SWITCH IS

RATED FOR USE ON A CIRCUIT CAPABLE OF

DELIVERING NOT MORE THEN THE RMS SYMM

AMPS AT THE VOLTAGE SHOWN.

RMS SYMM

AMPS

X1000

MAX

VOLTS

35

22

480

600

BREAKER/MFR/TYPE

ANY

ANY

ANY

ANY

ANY

ANY

AMPS

MAX

PER NEC

PER NEC

42 480 GE SGL4,SGP4,TB4,

THLC4,TLB4

SGLA,SGL6,SGP6,TB6

SKHA,SKL8,SKP8,TKL

400

400

600

800

42 480 I--T--E CJD6,HHJD6,

HHJXD6,HJD6,SCJD6,SHJD6

CLD6,HHLD6,HHLXD6,HLD6,

SCLD6,SHLD6

CMD6,HMD6,HND6,MD6,MXD6,

SCMD6,SHMD6,SMD6,SND6

400

400

600

600

800

800

42 480 SQUARE D LC,LI

MH

42 480 WESTH HKD,KDC,LCL,

TRI--PAC LA

HLD

TRI--PAC NB

42 480 ABB S5

S6

42 480 MERLIN GERIN

CJ600

600

800

400

400

600

800

400

800

600

1

200 480 FUSE ANY CLASS J 600

USE 75 °C MIN. CU/AL WIRE FOR POWER

CONNECTIONS. USE 60 °C MIN. CU WIRE FOR

CONTROLS.

USE COPPER OR ALUMINUM WIRE

FOR POWER TERMINALS

RECOMMENDED TIGHTENING

TORQUE 600 IN--LBS

483500--007

REV B

1. Torque specification

Figure 2-19 Typical Rating/Torque Label

007


Figure 2-20 Interconnection Diagram


ADV-6736

TP-6126 8/02

2.5.2

Engine Start Connection

WARNING

The generator engine start contacts are rated

2 amps @ 30 VDC/250 VAC.












Prevent the generator set from starting by moving the generator set master switch to the OFF position; disconnecting power to the generator engine start battery charger, if installed; and disconnecting all generator engine start battery cables, negative (--) leads first.

Connect the generator set remote starting circuit to the engine start connections located on the transfer switch contactor assembly.

The engine start terminals are labeled with a red decal. See Figure 2-21, Figure 2-22, and Figure 2-23 for the locations of the engine start contacts. Refer to the generator set installation manual for wire size specifications.

1

14

15

16 (Do not use)

1. Engine start contacts 14 and 15

Figure 2-21 Engine Start Contacts, 30--200 Amp

Switches

6126


14 15

1

1

4

27

24

21

18

15

12

9

6

26

23

20

17

14

11

8

5

2

13

10

7

4

1

25

22

19

16

3

2

GM21298


Figure 2-22 Engine Start Contacts, 225--400 Amp

Open-Transition Models

GM21311

1. Typical terminal block location

2. Decal


4. Auxiliary contacts 4--27 (see the schematic diagram for contacts closed on Normal or closed on Emergency)

Figure 2-23 Engine Start and Auxiliary Contact

Terminal Block, Programmed-Transition

Models and 600--4000 Amp



2.5.3

Auxiliary Contacts

Connect the auxiliary contacts to customer-supplied alarms, remote indicators, or other devices. Auxiliary contacts provide contacts that close when the transfer switch is in the Normal position and contacts that close when the transfer switch is in the Emergency position.

Each contact is rated 10 amps at 32 VDC or 250 VAC.

The table in Figure 2-24 lists the number of auxiliary contacts provided with each transfer switch.

Figure 2-23, Figure 2-25, and Figure 2-26 show the locations of the auxiliary contacts for different models.

Refer to the schematic diagram provided with the transfer switch to identify which auxiliary contacts are closed on Normal and which are closed on Emergency for 600--4000 amp models. Follow the wire size and tightening torque specifications shown on the decal on the transfer switch.

Auxiliary Position Indicating Contacts

(rated 10 amps @ 32 VDC/250 VAC)

Number of Contacts Closed on

Normal, Emergency

Switch Rating

(Amps)

30--104

150--400

150--400 *

600--800

1000--3000

Open-

Transition

2, 2

2, 2

—

2, 2

8, 8

Programmed-

Transition

—

2, 2

6, 6

6, 6

7, 7

4000 4, 4 4, 3

* Programmed-transition with switched neutral

Figure 2-24 Number of Auxiliary Contacts Available on Each Switch

31 29

32 30

13 11

1

6126

GM20601

12 10

1. Auxiliary contacts 10--13 and 29--32 (contacts shown with contactor in Normal position)

Figure 2-25 Auxiliary Contacts, 30--200 Amp



2.5.4

Controller Ground

Verify that the grounding wire is connected from the controller’s lower left mounting stud to the enclosure.

This connection provides proper grounding that does not rely upon the door hinges.

Note: Do not connect the controller harness to the contactor until instructed to do so in the voltage check procedure, Section 3.7.2. Disconnect the power before connecting or disconnecting the controller harness.

11 13

1

10 12

31 29

32 30

6126

1. Auxiliary contacts 10--13 and 29--32 (contacts shown with contactor in Normal position)

Figure 2-26 Auxiliary Contacts, 225--400 Amp



3.1 Introduction

This section explains the setup and test of the transfer switch.

Follow the instructions in this section after completing the physical installation described in the previous section.

Note: Be sure to perform the functional tests explained in Section 3.7 before putting the transfer switch into operation.

The instructions in this section explain how to set up the system to operate using factory default settings. This section includes:

D

D

D

D

D

D

D

D

User interface panel pushbuttons and LED indicators

DIP switch functions and settings

Main logic board input and output connections and default settings

Communications connections

Factory default settings for voltage, frequency, and time delay functions

Functional tests

Exerciser setup

Warranty registration

The transfer switch is designed to be set up and operated using the factory settings for time delays,

Section 3 Setup and Test

voltage and frequency pickup and dropout, and other system parameters. To view and change the system settings, a personal computer running the

MPAC-1000 t Setup Program is required.

See

TP-6135, Software Operation Manual, for instructions to use the Setup Program.

3.2 User Interface Panel

3.2.1

Pushbuttons and LED Indicators

The user interface panel is located on the transfer switch door. Figure 3-1 shows the user interface pushbuttons and LED indicators. The LEDs light steadily or flash to indicate different ATS conditions.

The tables in

Figure 3-2 and Figure 3-3 describe the functions of the pushbuttons and LED indicators.

Refer to the appropriate section for more details about functions listed in Figure 3-3 and Figure 3-2; see the Table of

Contents.

Figure 3-4 lists the fault conditions that cause the

Service Required LED to light or flash.

Steady illumination indicates that maintenance is needed; flashing indicates that service is required immediately.

1

1. User interface panel location

Figure 3-1 User Interface Panel

TP-6126 8/02

GM211077A

Section 3 Setup and Test 17

LED Indicator

Exercise

Not in Auto

Color

Amber

Load Control Active Amber

Red

Steady

Unloaded exercise is running.

Pre/post-transfer load control or peak shave functions are operating.

—

Position N

Position E

Position Off/

In-Phase Sync

Service Required

Red

Red

Amber

Red

Source N Available Green

Source E Available Green

Test Red

Time Delay LED Bar Amber

Contactor is in Normal positon.

Contactor is in Emergency position.

Contactor is in Off position

(programmed-transition models only).

Fault. Non-emergency is maintenance required.

Source N is available.

Source E is available.

Unloaded test is running.

LEDs step down to indicate time remaining in an active time delay or exercise period.

Figure 3-2 User Interface LED Indicators

—

—

—

—

—

—

Loaded test is running.

—

Pushbutton

Exercise

Lamp Test

Test

Time Delay

Description

Start and stop an exercise and set the exercise time.

Test LEDs or reset the Service Required

LED.

Start and stop a test.

End an active time delay.

(Does not end the exercise active or programmed-transition time delays.)

Figure 3-3 User Interface Pushbuttons

LED Illumination

Slow Flash

Loaded exercise is running.

—

Rapid Flash

When exercise button is pressed and held, rapid flashing indicates the exercise has been started and set.

Rapid flashing at any other time indicates that the exerciser is inhibited by the DIP switch setting.

—

— ATS is not set for automatic operation or a load shed (forced transfer to OFF) sequence is active.

—

—

In-phase monitor is operating

(open-transition models only).

Fault. Immediate maintenance is required.

—

—

—

—

3.2.2

Controller Reset

The controller can be reset without disconnecting power. Use the following procedure.

Controller Reset Procedure

1. Hold the Lamp Test button until the LEDs flash. Do not release the button.

2. Continue to hold the Lamp Test button in and press the End Time Delay button. The LEDs will flash when the controller resets.

Service Required

LED Illumination

Steady

Fault (See Section 4.3)

Auxiliary Switch Fault

Auxiliary Switch Open

Failure to Acquire Standby Source

Failure to Transfer

I/O Module Communications Lost

I/O Module Not Installed

I/O Module Not Found

Phase Rotation Fault

Remote Common Fault

External Low Battery

Figure 3-4 Service Required LED

18 Section 3 Setup and Test TP-6126 8/02

3.3 Controller Main Logic Board

DANGER

1

2

3

11

Hazardous voltage.



NOTICE




The controller’s main logic board is mounted in a plastic housing on the inside of the transfer switch enclosure door. It is not necessary to open the cover to access the

DIP switches or the PC connector on the circuit board.

Figure 3-6 shows the locations the DIP switches and connectors on the main logic board.

1

2

10

9

8

4

5

6

7

GM21364

1. I/O board connection (P3)

2. User interface connections

3. DIP switches

4. Serial port for PC connection (P6)

5. Preferred source switch connection (P7)

6. Supervised transfer switch connection (P8)

7. Programmed-transition interface board (PTIB) connection

(factory connection) (P9)

8. Ground wire

9. Contactor harness connection

10. Serial number decal

11. Terminal strip (inputs, output, Modbus connections) (TB1)

Figure 3-6 Controller Board Component Locations

3

1. Hinges

2. Access openings to DIP switches and PC connection

3. Latch

GM21079

Figure 3-5 Controller Housing

TP-6126 8/02 Section 3 Setup and Test 19

3.3.1

Main Logic Board DIP Switch

Settings

DIP switches on the main logic board control the test and exercise functions. A maintenance DIP switch inhibits transfer during ATS service. The factory settings for the

DIP switches are shown in Figure 3-8.

Before opening the transfer switch enclosure to check or change the DIP switch settings, open the circuit breakers to disconnect the power to the transfer switch.

The DIP switches are located on the controller’s main logic board on the inside of the enclosure door.

Figure 3-6 shows the locations of the switches on the controller circuit board. A decal on the logic assembly housing shows the DIP switch positions and settings

(see Figure 3-8). It is not necessary to remove the logic assembly cover to see or adjust the DIP switches.

Check the DIP switch settings and adjust if necessary for the application.

Note: Changing the position of the 1 week/2 week exercise DIP switch after the exerciser has been set does not change the time of the next scheduled exercise. The new DIP switch setting becomes effective after the next scheduled exercise. See Section 4.2.3 for more information about the exerciser.

Close and lock the enclosure door before energizing the transfer switch.

3.3.2

Main Logic Board Inputs and

Outputs

The controller main logic board’s inputs and outputs are factory-assigned to the functions shown in Figure 3-7.

Pre-Transfer Load Control Output.

Assigned to terminals TB1-1 and TB1-2. The load control output operates only during the transfer sequence between two live sources. When the output is activated, the contact opens for the programmed length of time before transfer (default setting=3 seconds) to allow controlled disconnection of selected loads. The contact closes at the time of transfer (default post-transfer time delay setting=0). The contact is not activated if the controller detects no available source.

See Section 4.2.5 for more information about the pre-transfer and post-transfer load control signal operation sequence. The pre- and post-transfer time delays can be adjusted using the optional setup program.

Load Bank Control Output. Assigned to terminals

TB1-3--TB1-5 (programmable). The load bank control output can be used to apply a load to the generator set during the exercise. The load bank control output closes or opens a contact that can be used to signal the load bank controller to operate. If the Normal source is lost during an exercise period, the load bank control output is deactivated to remove the load bank and allow the transfer of the building load to the emergency source.

Peak Shave/Area Protection Input.

Assigned to terminals TB1-6 and TB1-7 (programmable input #1).

Starts the generator set and transfers to the standby source, ignoring the Time Delay Engine Start and

Standby-to-Preferred time delays.

The system attempts to transfer to the preferred source when the input is removed.

The peak shave command is overridden if the standby source fails.

TB1 Input/Output Factory Setting

Non-programmable output Pre-transfer load control

Programmable output

Programmable input #1

Programmable input #2

Load bank control output

Peak shave/Area protection input

End time delay input

Figure 3-7 Terminal Strip Input and Output Factory

Settings

Figure 3-8 Logic Assembly Decal Showing DIP Switch Settings


End Time Delay Input. Assigned to terminals TB1-8 and TB1-9 (programmable input #2). Allows a remote signal to end an active time delay. The signal ends only the time delay that is active at the time the signal is applied.

Repeated signals are required to end additional time delays.

Does not end the programmed-transition time delays or an exerciser run.

Other Inputs and Outputs. Other input and output functions can be assigned to the programmable TB1 terminals.

Refer to Section 6 for lists of available programmable inputs and outputs.

Use the Setup

Program to change the input and output assignments if necessary.

Connections. Connect input and output leads to the controller terminal strip on the main logic board (MLB).

To gain access to the terminal strip, open the plastic housing by pushing up on the latch on the bottom of the cover and swinging the cover up and out. The cover is hinged at the top. Lift the cover off the hinges to remove it completely, if necessary. Refer to the label on the plastic housing or Figure 3-9 for the connections. Use

#12--24 AWG wire and tighten the connections to 0.5

Nm (4.4 in. lbs.).

The controller board terminal strip has two programmable inputs. Each input has a signal and a return connection. Connect inputs to terminals 6 and 7 or 8 and 9 on terminal strip TB1. Record the connections on the label provided. Use the setup program to assign the input functions if they are different from the default assignments shown in Figure 3-7.

The main logic board has one programmable output, which is factory-assigned to the load bank control output function. Connect to terminals 3 and 4 or 3 and 5 on terminal strip TB1. Use the setup program to assign the output function if it is different from the default assignment.

Note: Always replace the cover before energizing the transfer switch controls.

3.3.3

Communications Connections

The controller has two communications connections.

Serial Port. For connection to a personal computer to run the Setup Program software. This is a non-isolated

RS-232 port with a connection speed of 57.6 kbps.

Modbus rrrr Network Interface (MNI). For connection to building management systems, programmable logic controls, etc. This is a non-isolated RS-485 port with connection speeds of 9.6 kbps and 19.2 kbps. Use RTU

Modbus r is a registered trademark of Schneider Electric.

TP-6126 8/02

(remote terminal unit) protocol for communication through this port.

Connect the Modbus input and output to the terminals shown in Figure 3-9. Use #12--24 AWG twisted-pair wire; Belden cable #9841 or equivalent is recommended. Connect the shield to ground as shown in Figure 3-9.

Tighten the connections to 0.5 Nm

(4.4 in. lbs.).

Note: Contact Kohler Co.

for information about

Modbus r communication protocol.

TRANSFER

PRE-SIGNAL

10A@30VDC/250VAC

PROGRAMMABLE

OUTPUT

2A@30VDC/250VAC

PROGRAMMABLE

INPUT 1

PROGRAMMABLE

INPUT 2

MODBUS RS485

MODBUS RS485

B (+)

A (--)

B (+)

A (--)

Customer connections

Figure 3-9 Terminal Strip TB1 Connections

GM22366


3.4 Programmed-Transition

Interface Board (PTIB)

Programmed-transition model transfer switches use a programmed-transition contactor and a programmed-transition interface board (PTIB).

The

PTIB is mounted on the inside of the enclosure door.

The PTIB is factory-wired and requires no additional wiring in the field. Verify that the PTIB wiring harness is connected to the main logic board. See Figure 3-10 for the PTIB connector location.

2

1

3

GM21079

1. Controller assembly (located inside the enclosure door)

2. PTIB connection

3. PTIB

Figure 3-10 Programmed-Transition Interface Board

(PTIB)

3.5 System Settings and Time

Delays

The system can be operated using the factory settings listed in the following sections.

Use the Setup Program to change the controller time delays, pickup and dropout settings, inputs, outputs, and options if necessary.

3.5.1

System Parameters

The system parameter factory settings are shown in

Figure 3-11.

The controller voltage and frequency sensing are factory-set to the default values shown in

Figure 3-12. The voltage and frequency debounce time delays prevent nuisance transfers caused by brief spikes and dips in the power supply.

System Parameter

Open or programmed transition

Single/three phase

Operating voltage

Operating frequency (50 or 60 Hz)

Phase rotation

Commit to transfer (yes or no)

Factory Setting

Set to order

Set to order

Set to order

Set to order

ABC

No

Rated current

Operating mode:

Generator-toGenerator,

Utility-to-Generator, or

Utility-to-Utility

Set to order

Utility-to-Generator

In-phase monitor

In-phase monitor transfer angle

Disabled

0

Transfer mode

(automatic or non-automatic)*

Set to order

* The transfer mode (automatic or non-automatic) cannot be changed in the field.

Figure 3-11 System Parameters

Voltage and Frequency Sensing

Parameter

Undervoltage pickup

Default

90% of nominal

Undervoltage dropout

Overvoltage dropout

Overvoltage pickup

Voltage debounce time

Underfrequency pickup

Underfrequency dropout

Overfrequency dropout

Overfrequency pickup

Frequency debounce time

90% of pickup

110% of nominal

95% of dropout

0.5 sec.

90% of nominal

99% of pickup

101% of pickup

110% of nominal

3 sec.

Figure 3-12 Factory Settings, Voltage and Frequency


3.5.2

Time Delays

The factory settings for the time delays are shown in

Figure 3-13.

The pre-transfer time delays operate only when both sources are available.

These delays allow time to disconnect selected loads before transfer. The load control LED on the user interface lights when the pre-transfer signal is active.

The pre-transfer and post-transfer time delays overlap the preferred-to-standby and standby-to-preferred transfer time delays.

Adjustable Time Delays

Time Delay

Engine start

Preferred to standby

Standby to preferred

Off to standby (programmed-transition only)

Off to preferred (programmed-transition only)

Failure to acquire standby source

Pretransfer to standby signal

Pretransfer to preferred signal

Post-transfer to standby signal

Post-transfer to preferred signal

Engine cooldown

In-phase monitor synch

Figure 3-13 Factory Settings, Time Delays

Default

3 sec.

1 sec.

15 min.

1 sec.

1 sec.

1 min.

3 sec.

3 sec.

0 sec.

0 sec.

0 min.

30 sec.

3.6 Generator Set Preparation

WARNING

Hazardous voltage.

Moving rotor.



Disconnect all power sources to the transfer switch by opening upstream circuit breakers or switches to the transfer switch.

Prepare the generator set for operation. Check the oil level, coolant level, fuel supply, batteries, and items specified by the generator set installation or operation checklist or manual.

Move the generator set master switch to the OFF position; reconnect the generator engine start battery cables, negative (--) leads last; and reconnect power to the generator engine start battery chargers, if installed.

TP-6126 8/02

3.7 Functional Test

The functional test includes three checks:

D

D

D


Voltage Checks

Automatic Operation Test

Note: Perform these checks in the order presented to avoid damaging the ATS.

Read all instructions on the labels affixed to the automatic transfer switch.

3.7.1


If you have not already done so, test the contactor manual operation before proceeding to the voltage check and electrical operation test.

Note: Disable the generator set and disconnect the power by opening the circuit breakers or switches for both sources before manually operating the transfer switch.

Follow the instructions in Section 2.4 to check the transfer switch manual operation.

A contactor in normal and serviceable condition transfers smoothly without binding when operated manually. Do not place the transfer switch into service if the contactor does not operate smoothly without binding; contact an authorized distributor/dealer to service the contactor.

Note: Do not reconnect the power sources at this time.

Proceed to the voltage check procedure described in the following section.

3.7.2

Voltage Check

The voltage, frequency, and phasing of the transfer switch and the power sources must be the same to avoid damage to loads and the transfer switch. Compare the voltage and frequency ratings of the utility source, transfer switch, and generator set, and verify that the ratings are all the same.

Use the voltage check procedure explained in this section to verify that the voltages and phasing of all power sources are compatible with the transfer switch before connecting the power switching device and controller wire harnesses together.

Read and understand all instructions on installation drawings and labels on the switch. Note any optional accessories that have been furnished with the switch and review their operation.


Note: Source N is the source connected to the normal side of the contactor. Source E is the source connected to the emergency side of the contactor.

The voltage check procedure requires the following equipment:

D

A digital voltmeter (DVM) with electrically insulated probes capable of measuring the rated voltage and frequency

D

A phase rotation meter

DANGER

Hazardous voltage.



Testing live electrical circuits.

Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests.

Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically.

(600 volts and under)

Voltage Check Procedure

Note: Perform voltage checks in the order given to avoid damaging the transfer switch.

1. Verify that the generator set master switch is in the

OFF position and both power sources are disconnected from the transfer switch.

2. Disconnect the power switching device and controller wiring harnesses at the inline disconnect plug, if they are connected.

3. Manually operate the transfer switch to position E.

See Section 2.4.

4. If Source N is a generator set, move the generator set master switch to the RUN position.

The generator set should start.

5. Close the Source N circuit breaker or switch.

6. Use a voltmeter to check the Source N (normal) phase-to-phase and phase-to-neutral (if applicable) terminal voltages and frequency.

a. If Source N is the utility and the measured input does not match the voltage and frequency shown on the transfer switch nameplate,

STOP! Do not proceed further in installation because the transfer switch is not designed for the application—call your distributor/dealer to order the correct transfer switch.

b. If Source N is a generator set and the generator set output voltage and frequency do not match the nominal system voltage and frequency shown on the transfer switch nameplate, follow the manufacturer’s instructions to adjust the generator set. The automatic transfer switch will only function with the rated system voltage and frequency specified on the nameplate.

7. Use a phase rotation meter to check the phase rotation at the Source N (normal) terminals.

Rewire the transfer switch Source N terminals to obtain the correct phase sequence if necessary.

Note: The default setting for the phase rotation on the controller is ABC. If the application uses a phase rotation of CBA, use the Setup

Program to change the phase rotation setting on the controller.

8. If the source is a generator set, stop the generator set by moving the master switch to the OFF position.

9. Disconnect Source N by opening upstream circuit breakers or switches.

10. Manually operate the transfer switch to position N.

11. Repeat steps 4 through 8 for Source E.

Then proceed to step 17.

12. Disconnect both sources to the transfer switch by opening the circuit breakers or switches.

13. Connect the power switching device and controller wiring harnesses together at the inline disconnect plug.

Note: Do not connect or disconnect the controller wiring harness when the power is connected.

14. Check the DIP switch settings.

Verify that the

TEST DIP switch is in the loaded position before proceeding with the next test.

15. Close and lock the transfer switch enclosure door.


16. Reconnect both power sources by closing the circuit breakers or switches.

17. Move the generator set master switch to the AUTO position.

Note: If the engine cooldown time delay setting is not set to zero (default setting), the generator set may start and run until the

Time Delay Engine Cooldown (TDEC) ends.

18. Proceed to the automatic operation test.

3.7.3

Automatic Operation Test

Check the transfer switch’s automatic control system immediately after the voltage check. The test sequence simulates a loss of the normal source, starts the generator set, and transfers the load to the emergency source, executing all time delays that are set up to operate during a loss of the normal source. When the test is ended in step 7 of the procedure, the transfer switch transfers the load back to the normal source and removes the engine start signal, executing all appropriate programmed time delays.

Refer to Section 4.2.2 for a description of the test sequence of operation.

Note: If the standby source fails during a test, the ATS will immediately attempt to transfer to the preferred source.

Optional Switches.

If the ATS is equipped with a preferred source switch, check the switch position before proceeding with the automatic operation test.

The test procedure assumes that Source N is the preferred source.

If the transfer switch is equipped with a supervised transfer switch, verify that it is set to the Auto position.

See Section 6 for more information about optional switches.

Note: Close and lock the enclosure door before starting the test procedure.

DANGER

Automatic Operation Test Procedure

1. Check the controller LED indicators to verify that the Position N and Source N Available indicators are lit.

2. Press the lamp test button and check that all controller LEDs illuminate.

3. Verify that the generator set master switch is in the

AUTO position.

4. Press the TEST button on the controller to start the test. The TEST LED flashes to indicate that the

ATS controller is set up to transfer the load during the test.

5. Verify that the generator set starts after the engine start delay times out. Check that the Source E

Available LED lights.

6. Verify that the switch transfers the load to Source E.

a. Open-Transition Models: After the preferred-to-standby time delay, verify that the

Position N LED goes out and the Position E

LED lights, indicating that the switch has transferred the load to Source E.

b. Programmed-Transition Models: After the preferred-to-off time delay, verify that the

Position N LED goes out and the Position OFF

LED lights. After the off-to-standby time delay, check that the Position E LED lights, indicating that the switch has transferred the load to

Source E.

7. Push the Test button to end the test.

8. Verify that the switch transfers the load back to

Source N.

a. Open-Transition Models: After the standby-to-preferred time delay, verify that the

Position E LED goes out and the Position N

LED lights, indicating that the switch has transferred the load to Source N.

b. Programmed-Transition Models: After the standby-to-off time delay, verify that the

Position E LED goes out and the Position OFF

LED lights.

After the off-to-preferred time delay, check that the Position N LED lights, indicating that the switch has transferred the load to Source N.

Hazardous voltage.



TP-6126 8/02 Section 3 Setup and Test 25

Note: The generator set may have an engine cooldown time delay that causes the generator set engine to run after the transfer switch engine start signal is removed.

This completes the functional test.

3.8 Exerciser Setup

The installer must activate the exerciser. Press and hold the Exercise button for approximately 3 seconds until it flashes to activate the exerciser, start an exercise run, and set the time and date of the next exercise run. The exercise time is set to the time that the button is pushed.

The default setting for the exerciser run duration is 30 minutes. The time delay LEDs show the time remaining in the exercise run. Press and hold the exercise button again to end the exercise period early, if desired.

Note: Pressing the end time delay button does not end an exercise run.

Set the exerciser period (every week or every 2 weeks) and load condition by using DIP switches on the controller circuit board.

The factory settings for the exerciser are shown in Figure 3-14.

Exerciser Parameter Factory Setting

1 week/2 week exercise (DIP switch) 1 week

Disable/enable exercise (DIP switch)

Enable

Load/no load exercise (DIP switch)

No load

Run duration 30 minutes

Figure 3-14 Exerciser Factory Settings

Use the Setup Program to change the exerciser run duration, if desired.

See Section 4.2.3 for more information about the exerciser.

The exerciser can be set without starting the generator set, if necessary. Use the following procedure.

Exerciser Setting Procedure

1. Move the disable/enable exercise DIP switch to the

DISABLE position and close the enclosure door.

The Exercise LED flashes rapidly to indicate that the exerciser is disabled.

2. Press and hold the exercise button until the

Exercise LED goes out for approximately 3 seconds and then starts to flash again.

3. Move the disable/enable exercise DIP switch back to the ENABLE position.

4. Close and lock the enclosure door.

5. Verify that the EXERCISE LED is not flashing.

The exerciser time is set to the time that the button is pushed. The exerciser will run in one or two weeks according to the 1 week/2 week DIP switch position.

3.9 Warranty Registration

The transfer switch seller must complete a Startup

Notification Form and submit it to the manufacturer within 60 days of the initial startup date.

A Startup

Notification Form is included with generator sets and covers all equipment in the standby system. Standby systems not registered within 60 days of startup are automatically registered using the manufacturer’s ship date as the startup date.


4.1 Introduction

This section contains descriptions and flowcharts for typical transfer switch operating sequences.

This section also describes faults and provides other information related to the controller operation.

On systems not equipped with the preferred source selector switch, the preferred source is the source connected to the Normal side of the power switching device. The source connected to the Emergency side of the contactor is the standby source.

4.2 Sequence of Operation

4.2.1

Automatic Operation, Open- and

Programmed-Transition Switches

Typical ATS operation in utility-to-generator set mode is divided into two sequences:

D

Failure of the Normal (preferred) power source and the resulting load transfer to the Emergency

(standby) source.

D

Restoration of the preferred power source and the resulting load transfer back to the preferred source.

Events such as the failure of the generator set to start can change the sequence of operation.

If the emergency source fails and the normal source is not available, the transfer switch controller powers down until one of the sources returns.

Figure 4-1 Illustrates the transfer sequence when the normal source fails, and Figure 4-2 illustrates the sequence when it returns.

Figure 4-3 shows the operation of the user interface LEDs during loss and restoration of the normal source.

Time Delays. Time delays before load transfer prevent nuisance transfers during brief power interruptions. The voltage and frequency debounce time delays prevent nuisance transfers caused by brief spikes and dips in the power supply. See Section 3.5 for the default settings for the time delays and debounce times.

Loss of Phase. If the system detects a loss of phase in the connected source, it attempts to transfer to an

Section 4 Operation

alternate source. The system considers a phase lost if its phase is 45 degrees from the rotation setting. The controller logs loss of phase events in the event history.

Programmed-Transition Switches.

Programmed transition switches provide an OFF position during transfer between two sources. The adjustable time off period allows residual voltages in the load circuits to decay before connecting to the second source. During the off period, the ATS main contacts are open and neither source powers the load.

The off-to-standby and off-to-preferred time delays control the length of the off period for programmed-transition switches. The time delays are factory-set to the defaults shown in Figure 3-13. The time delays can be changed using the optional Setup

Program.

The End Time Delay Button and Remote Bypass command do not override the off-to-standby and off-to-preferred time delays.

Normal (preferred) power source fails

Time delay engine start

Time delay preferred-to-standby

Transfer to OFF position

(programmed-transition only)

Time delay off-to-standby


Transfer to emergency (standby) source

Post-transfer load control (as programmed*)

* See the Setup Program Operation Manual.

Figure 4-1 ATS Sequence of Operation, Transfer to

Emergency (standby source)

TP-6126 8/02 Section 4 Operation 27

Normal (preferred) power source returns

Pre-transfer load control (as programmed*)

Time delay standby-to-preferred

In-phase monitor (open-transition only, as programmed*)

Transfer to OFF position


Time delay off-to-preferred


Transfer to normal (preferred) source


Time delay engine cooldown (TDEC)

(as programmed*)

Engine start signal removed


Figure 4-2 ATS Sequence of Operation, Return to

Normal (preferred source)

Loss of Normal Source

Engine Start Time Delay

Preferred-to-Standby Time Delay

Post-transfer to Standby Load Control

Standby-to-Preferred Time Delay

Pre-transfer to Preferred Load Control

Off-to-Preferred Time Delay (programmed-transition only)

Post-transfer to Preferred Load Control

Engine Cooldown Time Delay (Default = 0)

N

Available

X

X

X

X

X

N

Position

X

X

X

Figure 4-3 User Interface LED Indicators During Loss of Normal Source

LED Indicators

OFF

Position

E

Available

X

X

X

X

X

X

X

X

E

Position

X

X

X

Load

Control

X

X

X

28 Section 4 Operation TP-6126 8/02

4.2.2

System Test

A system test simulates a preferred source failure and performs the transfer sequence. Press and release the test button to start the test. Press and release the test button again to end the test. The test sequence does not start if the ATS is in the standby position.

A test sequence can also be started or ended through the setup software. See the Setup Program Operation manual.

The Test LED flashes to indicate a loaded test or lights steadily to indicate a test without load. Use the test DIP switch to select loaded or unloaded tests. See Section

3.3.1 for DIP switch locations and settings.

Figure 4-4 and Figure 4-5 illustrate the following test sequences. Figure 4-6 shows the operation of the user interface LEDs during the test sequence.

Test without Load. The test without load sequence starts the generator set but does not transfer the load.

The generator set continues to run until the test button is pushed again.

Test with Load. The test with load sequence simulates a preferred source failure and activates the pre- and post-transfer load control sequences as programmed.

Refer to Section 4.2.5 for additional information about pre-transfer time delays.

The test remains active until the test button is pushed again or until a remote test signal is received. If the standby source fails during a test cycle, the system immediately transfers back to preferred.

The test sequence executes all time delays that are set up to operate during a normal sequence of operation.

Press the End Time Delay button to shorten the time delays while they are running, if desired. (The End Time

Delay button does not end programmed-transition time delays.)

At the start of the test, the ATS simulates a preferred source failure and signals the generator set to start.

When the standby source is available and the time delay preferred-to-standby expires, the ATS transfers the load if the test DIP switch is set for a loaded test.

When the test button is pressed again, the ATS transfers the load back to the preferred source, if available, after the standby-to-preferred time delay. The ATS removes the generator engine start signal after the related time delays expire. (The generator set may continue to run if the generator set controller provides an additional engine cooldown time delay.)

Test started

Time delay engine start (TDES)

Generator set engine start contacts close

Load bank control output activated (as programmed*)

Test ended

Load bank control output deactivated (as programmed*)


(as programmed)* (default = 0)

Generator set engine start signal removed


Figure 4-4 Test Without Load Sequence


Test started

Time delay engine start (TDES)

Generator set engine start contacts close


Preferred-to-standby time delay

In-phase monitor or transfer to off

(as programmed*)

Transfer to standby source


A

A

Test ended

Standby-to-preferred time delay



(as programmed*)

Transfer to preferred source



(as programmed*) (default = 0)

Generator set engine start contacts open


Figure 4-5 Test with Load Sequence

System Test

Engine Start Time Delay


Pre-transfer to Standby Load Control

Off-to-Standby Time Delay


Post-transfer to Standby Load Control

Pre-transfer to Preferred Load Control

Off-to-Preferred Time Delay


Post-transfer to Preferred Load Control

Engine Cooldown Time Delay

(Default = 0)

N

Available

X

X

X

X

X

X

X

X

X

N

Position

X

X

X

X

X

OFF

Position

Figure 4-6 User Interface LED Indicators During a Loaded Test

X

X

E

Available

E

Position

X

X

X

X

X

X

X

X

X

X

Load

Control

X

Test

(flashing)

X

X

X

X

X

X

X

X

X

X

X

X


4.2.3

Exerciser

Activate the exerciser after ATS installation by pressing and holding the exercise button until the exercise LED flashes quickly. See Figure 3-1 for the location of the

Exercise button and LED on the user interface panel.

Press the Exercise button while the exercise is running to end the exercise early, if desired.

Figure 4-7 shows the exerciser factory default settings.

The exercise mode is set through the Setup Software.

All other settings in Figure 4-7 are set through DIP switches on the contoller’s main logic board.

See

Section 3.3.1.

Figure 4-8 describes the exercise LED operation.

Exerciser Parameter

1 week/2 week exercise

Disable/enable exercise

Load/no load exercise

Run duration

Exercise mode

Factory Setting

1 week

Enable

No load

30 minutes

Switch Input

Figure 4-7 Exerciser Factory Settings

Exerciser LED

Steady Illumination

Slow Flash (1 Hz)

Rapid Flash (4 Hz)

Indicates

Unloaded exercise active.

Loaded exercise active

When exercise button is pressed and held, rapid flashing indicates the exercise has been started and set.

Rapid flashing at any other time indicates that the exercise is inhibited by the DIP switch setting.

Figure 4-8 Exerciser LED Indicator

Loaded/Unloaded Exercise.

A DIP switch on the controller circuit board allows the selection of loaded or unloaded exercise runs. (See Section 3.3 for DIP switch locations.) Selecting unloaded exercise allows the ATS to start and run the generator set without transfering the building load.

The exercise LED flashes to indicate a loaded exercise.

The exercise sequence starts the generator set engine immediately. and activates the pre-transfer load control sequence.

The in-phase monitor or programmed-transition time delays operate if programmed. The post-transfer load control sequence operates as programmed after the load is transferred.

See Figure 4-9 and Figure 4-10 for the exerciser sequences of operation.

Figure 4-11 shows the operation of the user interface LEDs during the exercise run. Refer to Section 4.2.5 for additional information about pre-transfer time delays.

Exercise Mode. The exerciser is factory-set to operate in switch input mode, which uses the Exercise button on the user interface to start, stop, and set the exerciser, and the 1 week/2 week DIP switch to determine the exercise schedule.

Calendar modes with and without override are also available. The Setup Program software is required to select and set up the exerciser calendar modes. See the

Setup Program Operation manual.

The calendar mode overrides the exercise button on the user interface. Pressing the exercise button when the exerciser is set for calendar mode will not start an exercise or set the exercise time.

Calendar mode with override allows the starting and setting of the exerciser by pressing the exercise button.

Pressing the exercise button while in calendar mode with override resets the exerciser to the switch input mode.

Exercise Schedule. The exercise repeats at the same time each week or every two weeks, depending on the

1 Week/2 Week DIP switch position. See Section 3.3

for the DIP switch location.

Note: The exerciser clock is accurate to within 1 minute per month.

Pressing the exercise button starts the exercise and sets the time for the next exercise according to the position of the 1 week/2 week DIP switch. Changing the

1 week/2 week DIP switch position does not change the time of the next exercise because it has already been scheduled.

The new DIP switch setting becomes effective after the next scheduled exercise.

The system skips the exercise period if it is scheduled to start when the ATS is running under the following conditions:

D

The ATS is running a test cycle initiated by the Test button on the user interface.

D

The ATS is running on the standby source because the preferred source is not available.

D

The ATS is running on the standby source because of a peak shave/area protection command.

Exercise Duration. The default (factory) setting for the run duration is 30 minutes. If the generator set fails during an exercise period, the switch immediately transfers back to the preferred source. Use the Setup

Program to change the run duration, if desired.


Load Bank Control. The load bank control output can be used to apply a load to the generator set during the exercise.

The load bank control output provides a contact closure that can be used to signal the load bank controller to operate. If the Normal source is lost during an exercise period, the load bank control output contact opens to remove the load bank and allow the transfer of the building load to the emergency source. See Section

3.3.2 for the load bank control output connection.

Exercise button pressed or scheduled exercise signaled to begin

Generator set engine start (immediate)

Load bank control output activated (as programmed*)

Exercise time period ends or exercise button pressed

Load bank control output deactivated (as programmed*)

Time delay engine cooldown

(as programmed*)



Figure 4-9 Exercise without Load Sequence

Exercise button pressed or scheduled exercise signaled to begin

Generator set engine start

Time delay preferred to standby


In-phase monitor or transfer to off (as programmed*)



Exercise time period ends or exercise button pressed

Time Delay standby to preferred


In-phase monitor or transfer to off (as programmed*)



Time delay engine cooldown (as programmed*)



Figure 4-10 Exercise with Load Sequence


Loaded Exercise


Pre-Transfer to Standby Load Control

Off-to-Standby Time Delay


In-Phase Synch (as programmed;

N/A for programmed-transition models.)

Post-Transfer to Standby Load Control

Pre-Transfer to Preferred Load Control

Off-to-Preferred Time Delay


Post-Transfer to Preferred Load Control

Engine Cooldown Time Delay

(Default = 0)

N

Available

X

X

X

X

X

X

X

X

X

N

Position

X

X

X

X

OFF

Position

LED Indicators

E

Available

E

Position

X

X

X X

X

(flashing)

X

Figure 4-11 User Interface LED Indicators During a Loaded Exercise

X

X

X

X

X

X

X

X

Load

Control

X

Exercise

(flashing)

X

X

X

X

X

X

X

X

X

X

X

X


4.2.4

Peak Shave/Area Protection

Operation Sequence

The peak shave input signals the transfer switch to start the generator set and transfer to the standby source.

The engine start (TDES) time delay is ignored.

When the peak shave input is removed, the system transfers back to preferred (if available) and removes the generator engine start signal. The default setting ignores the standby-to-preferred time delay when transferring back to preferred.

Note: The setup software can be set to bypass or execute the standby-to-preferred time delay during the peak shave sequence. See the Setup

Program Operation Manual.

See Figure 4-12 for the sequence of operation.

Peak Shave/Area Protection signal received by controller

Immediate generator set engine start

Pre-transfer load control (as programmed)

In-phase monitor or transfer to off (as programmed)

Preferred to standby time delay


Post-transfer load control (as programmed)

Peak shave/area protection signal removed

Pre-transfer load control

(as programmed)


(as programmed)

Standby to preferred time delay

(as programmed)

[


Post-transfer load control (as programmed)

Time delay engine cooldown

(as programmed; default = 0)*



[ Default settings bypass this time delay

Figure 4-12 Peak Shave/Area Protection Sequence


4.2.5

Pre- and Post-Transfer Load

Control Sequence

The pre-transfer and post-transfer load control time delays operate during transfer between two live sources, such as during a loaded test sequence or a loaded exercise. The load control LED lights when the pre- and post-transfer signals are active.

The pre-transfer load control time delays overlap the preferred-to-standby and standby-to-preferred time delays. The longer delay determines the time delay before transfer.

The timelines in Figure 4-13 illustrate the pre-transfer time delay sequence using the default settings. (The default settings for the post-transfer signals are equal to zero.) The default setting for the preferred-to-standby time delay is 1 second, and the default setting for the pre-transfer time delay is three seconds. The time delay before transfer is equal to the longer time delay, which is

3 seconds. When transferring back to the preferred source, the standby-to-preferred time delay is 15 minutes. The pre-transfer signal operates during the final 3 seconds before transfer to the preferred source.

The total time delay before transfer back to preferred

(using the default settings) is 15 minutes.

Pre-Transfer Load Control Signal, 3 Seconds

Preferred-to-Standby Time Delay, 1 second

Transfer to Standby

3 2 1 0

Time before Transfer, in Seconds

Standby-to-Preferred Time Delay, 15 minutes

Pre-Transfer Load Control Signal, 3 Seconds

Transfer to Preferred

15 minutes

Time before Transfer

Figure 4-13 Pre-Transfer Time Delay Operation (default settings)

3 0


4.3 Faults

4.3.1

Service Required LED

The following faults cause the Service Required LED to flash, indicating that immediate service is required:

D

D

D

D

D

D

Auxiliary switch fault

Auxiliary switch open


Failure to transfer

Phase rotation fault

Input/output module faults (see Section 6.5.1)

Find and correct the cause of the fault before trying to reset the controller.

The cause of the fault may be shown by the other LEDs on the user interface; check the Source Available, Position, Load Control, Time

Delay, Exercise, and Test LEDs to diagnose the cause of the faults. If the LEDs do not reveal the cause of the fault condition, connect a PC to the controller and use the

Setup Program to view the event history. The event history lists fault conditions and transfers.

See the software operation manual for more information and instructions.

After correcting the fault condition, press the Lamp Test button for approximately 5 seconds until the LEDs flash twice to clear the Service Required LED.

4.3.2

Auxiliary Switch Faults

An Auxiliary Switch Fault occurs if the controller cannot determine the contactor switch position. The Service

Required LED flashes.

The fault clears when the controller can detect the switch position. Depress the Lamp Test button until the

LEDs flash to clear the Service Required LED.

4.3.3

Failure to Acquire Standby

Source

A fault occurs if the unit attempts to start the generator set but the standby source does not appear after the

Acquire Standby Source to Failure time delay.

The

Service Required LED illuminates. Some conditions that may cause this fault are failure of the generator set to start, no voltage output from the generator, or an error in sensing the voltage output from the generator set.

The fault clears when the system acquires a standby source. Depress the Lamp Test button until the LEDs flash to clear the Service Required LED.

4.3.4

Failure to Transfer

If the unit fails to transfer on command, the controller waits 1 second and then initiates another 200 msec attempt to transfer. If the in-phase monitor is operating, the system waits 1 second and then begins monitoring the source phases in preparation for transfer. When the sources are in phase, the system attempts to transfer.

After three unsuccessful attempts to transfer, the system stops attempting to transfer and generates a fault. The Service Required LED illuminates.

The fault clears when the contactor transfers successfully. Depress the Lamp Test button until the

LEDs flash to clear the Service Required LED.

4.3.5

Phase Rotation Faults

A fault occurs if the phase rotation of an input channel does not match the system’s phase rotation direction setting (ABC or CBA). The unit will not transfer to a source if the source’s phase rotation does not match the system setting. If the system detects a phase rotation fault in the connected source, it attempts to transfer to an alternate source that has the correct phase rotation.

The controller logs phase rotation faults in the event history.

If the system detects phase rotation faults on both sources, the Service Required LED lights. The system does not transfer from the connected source.

4.4 Controller Power Supply

The controller is powered by the sources connected to the transfer switch. The “dark time” is that period of time when neither source is available. During the dark time, capacitors maintain the controller power for about 15 seconds.

The capacitors require approximately one hour to completely recharge after a power loss.

The controller’s time, date, and all controller settings, including time delays, system parameters, pickups and dropout settings, and input/output assignments, are maintained by a controller battery during power outages.


5.1 Introduction

Regular preventive maintenance ensures safe and reliable operation and extends the life of the transfer switch.

Preventive maintenance includes periodic testing, cleaning, inspection, and replacement of worn or missing components. Section 5.4 contains a service schedule for recommended maintenance tasks.

A local authorized distributor/dealer can provide complete preventive maintenance and service to keep the transfer switch in top condition. Unless otherwise specified, have maintenance or service performed by an authorized distributor/dealer in accordance with all applicable codes and standards.

See the Service

Assistance section in this manual for how to locate a local distributor/dealer.

Keep records of all maintenance or service.

Replace all barriers and close and lock the enclosure door after maintenance or service and before reapplying power.

WARNING

Section 5 Scheduled Maintenance

DANGER

Hazardous voltage.



DANGER

Hazardous voltage.




DANGER












Hazardous voltage.



WARNING

Hazardous voltage.

Moving rotor.



TP-6126 8/02 Section 5 Scheduled Maintenance 37

Grounding the transfer switch. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open main circuit breakers of all power sources before servicing equipment. Configure the installation to electrically ground the transfer switch and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground, as the chance of electrocution increases under such conditions.

Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergize all power sources before servicing. Open the main circuit breakers of all transfer switch power sources and disable all generator sets as follows: (1) Move all generator set master controller switches to the OFF position.

(2) Disconnect power to all battery chargers. (3) Disconnect all battery cables, negative (--) leads first. Reconnect negative (--) leads last when reconnecting the battery cables after servicing. Follow these precautions to prevent the starting of generator sets by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. Before servicing any components inside the enclosure: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Test circuits with a voltmeter to verify that they are deenergized.

Short circuits.

Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage.

Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE

Hardware damage.

The transfer switch may use both

American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE




5.2 Testing

5.2.1

Weekly Generator Set Exercise

Use the exerciser or a manual test to start and run the generator set under load once a week to maximize the

38 Section 5 Scheduled Maintenance reliability of the emergency power system. Press the

Test button on the controller front panel to start and end the test. The Test LED flashes during a test with load or lights steadily during a test without load. Use the DIP switch to set the system for a loaded test or use a load bank and the load bank control output to run loaded without transferring the building load.

See Sections

4.2.2 and 4.2.3 for more information about the exercise and test functions.

5.2.2

Monthly Automatic Control

System Test

Test the transfer switch’s automatic control system monthly. See Section 3.7.3 for the test procedure.

D

Verify that the expected sequence of operations occurs as the switch transfers the load to the emergency source when a preferred source failure occurs or is simulated.

D

Observe the indicator LEDs included on the transfer switch to check their operation.

D

Watch and listen for signs of excessive noise or vibration during operation.

D

After the switch transfers the load to the standby source, end the test and verify that the expected sequence of operations occurs as the transfer switch retransfers to the preferred source and signals the generator set to shut down after a cooldown period.

D

On programmed-transition units, verify that the time delay in the OFF position functions during transfer to the standby source and transfer back to the preferred source.

5.3 Inspection and Service

Contact an authorized distributor/dealer to inspect and service the transfer switch annually and also when any wear, damage, deterioration, or malfunction of the transfer switch or its components is evident or suspected.

5.3.1

General Inspection

External Inspection. Keep the transfer switch clean and in good condition by performing a weekly general external inspection of the transfer switch for any condition of vibration, leakage, excessive temperature, contamination, or deterioration.

Remove accumulations of dirt, dust, and other contaminants from the transfer switch’s external components or enclosure with a vacuum cleaner or by wiping with a dry cloth or brush.

TP-6126 8/02

Note: Do not use compressed air to clean the transfer switch because it can cause debris to lodge in the components and damage the switch.

Tighten loose external hardware. Replace any worn, missing, or broken external components with manufacturer-recommended replacement parts.

Contact a local authorized distributor/dealer for specific part information and ordering.

Internal Inspection. Disconnect all power sources, open the transfer switch enclosure door, and inspect internal components monthly or when any condition noticed during an external inspection may have affected internal components.

Contact an authorized distributor/dealer to inspect and service the transfer switch if any of the following conditions are found inside the transfer switch.

D

Accumulations of dirt, dust, moisture, or other contaminants

D

Signs of corrosion

D

Worn, missing, or broken components

D

Loose hardware

D

Wire or cable insulation deterioration, cuts, or abrasion

D

Signs of overheating or loose connections: discoloration of metal, melted plastic, or a burning odor

D

Other evidence of wear, damage, deterioration, or malfunction of the transfer switch or its components.

If the applicaton does not allow a power interruption for the time required for the internal inspection, have an authorized distributor/dealer perform the internal inspection.

5.3.2

Other Inspections and Service

Have an authorized distributor/dealer perform scheduled maintenance, service, and other maintenance that ensures the safe and reliable operation of the transfer switch.

See Section 5.4,

Service Schedule, for the recommended maintenance items and service intervals.

Have an authorized distributor/dealer repair or replace damaged or worn internal components with manufacturer-recommended replacement parts.

TP-6126 8/02 Section 5 Scheduled Maintenance 39

5.4 Service Schedule

Follow the service schedule below for the recommended service intervals. Have all service performed by an authorized distributor/dealer except for activities designated by an X, which may be performed by the switch operator.

System Component or Procedure

ELECTRICAL SYSTEM

Check for signs of overheating or loose connections: discoloration of metal, melted plastic, or a burning odor

Check the contactor’s external operating mechanism for cleanliness; clean and relubricate if dirty *

Inspect wiring insulation for deterioration, cuts, or abrasion. Repair or replace deteriorated or damaged wiring

Tighten control and power wiring connections to specifications

Check the transfer switch’s main power switching contacts’ condition; clean or replace the main contacts or replace the contactor assembly as necessary

CONTROL SYSTEM

Exercise the generator set under load

See

Section

5.3.1

5.3.1

5.3.1

2.5

5.3.2

Visually

Inspect Check

X

X

X

D

X

D

D

Adjust,

Repair,

Replace

D

D

Clean

D (clean and lube)

D

Test

D

Frequency

Y

Y

Y

Y

Y

Test the transfer switch’s automatic control system

5.2.1

4.2.3

5.2.2

3.7.3

3.2

X

X

X

W

M

Test all indicators (LEDs) and all remote control systems for operation

D D D D Y

GENERAL EQUIPMENT CONDITION

Inspect the outside of the transfer switch for any signs of excessive vibration, leakage, high temperature, contamination, or deterioration *

Check that all external hardware is in place, tightened, and not badly worn

Inspect the inside of transfer switch for any signs of excessive vibration, leakage, high temperature, contamination, or deterioration*

Check that all internal hardware is in place, tightened, and not badly worn

5.3.1

5.3.1

5.3.2

5.3.2

X

X

D

X

X

D

D

X

D

X

D

M

M

Y

Y

* Service more frequently if the transfer switch is operated in dusty or dirty areas.

See Section: Read these sections carefully for additional information before attempting maintenance or service.

Visually Inspect: Examine these items visually.

Check: Requires physical contact with or movement of system components, or the use of nonvisual indications.

Adjust, Repair, Replace: Includes tightening hardware and lubricating the mechanism. May require replacement of components depending upon the severity of the problem.

Clean: Remove accumulations of dirt and contaminants from external transfer switch’s components or enclosure with a vacuum cleaner or by wiping with a dry cloth or brush. Do not use compressed air to clean the switch because it can cause debris to lodge in the components and cause damage.

Test: May require tools, equipment, or training available only through an authorized distributor/dealer.

Symbols used in the chart:

X=The transfer switch operator can perform these tasks.

D=An authorized distributor/dealer must perform these tasks.

W=Weekly

M=Monthly

Q=Quarterly

S=Semiannually (every six months)

Y=Yearly (annually)

40 Section 5 Scheduled Maintenance TP-6126 8/02

Section 6 Accessories

6.1 Introduction

This section describes the installation and/or operation of the following accessories:

D

MPAC Setup Program

D

Control Switches:

D

Preferred source switch

D

Supervised transfer switch

D

In-phase monitor

D

Programmable inputs and outputs:

D

Main logic board terminal strip

D

Input/output modules

D

Load shed (Forced transfer to OFF)

D

Security cover

D

Battery charger

6.2 Setup Program

The optional MPAC Setup Program allows you to use a personal computer to view and adjust system parameters, voltage and frequency pickup and dropout settings, time delays, input and output functions, and other system parameters. The software also includes a time-stamped event log that is useful for system diagnostics and troubleshooting. Refer to the Setup

Program Operation Manual for more information.

6.3 Control Switches

Two control switches are available, the preferred source switch and the supervised transfer control switch. The switches are mounted on the enclosure door.

See

Figure 6-1 for typical switch locations.

Note: Factory-installed switches are factory-wired and require no additional wiring in the field.

1

ADV-6698A

1. Preferred source switch and supervised transfer control switch location

Figure 6-1 Control Switch Locations

6.3.1

Preferred Source Switch

The two-position, key-operated preferred source selector switch allows selection of either power source as the preferred source. The key can be removed with the switch in either position, locking the switch into the selected position.

The preferred source selection cannot be changed remotely through software or the

Modbus r connection. Figure 6-2 shows the preferred source selector switch.

The transfer switch seeks and transfers to the preferred source whenever it is available. Source N is always the source connected to the Normal side of the transfer switch, and Source E is always connected to the

Emergency side.

Generator engine start relays are assigned to the the source (Source N or Source E). The engine start relays do not change when the preferred source switch position changes. This prevents the need to change the wiring of the engine start relay(s) when the preferred source changes.

TP-6126 8/02 Section 6 Accessories 41

GM21287

Figure 6-2 Preferred Source Selector Switch

Operating Modes. The transfer switch is factory-set for the generator set-to-utility mode of operation.

This mode uses one generator set, which is connected to the

Emergency side of the contactor (Source E), and one engine start relay. The engine start relay connections are located on the contactor on 30--400 amp units, and on the customer-connection terminal block on larger units (see Section 2.5.2). The engine start contact is assigned to the connected generator set and does not change assignment when the preferred source switch position is changed. In this mode, if the preferred source switch is set to Source E, then the system operates the generator set indefinitely, transferring to utility power only if the generator set fails.

Use the setup program to change the mode to generator set-generator set or utility-utility if necessary.

The generator set-generator set mode uses two generator sets and requires the assignment of a second engine start output. Use the setup program to assign one of the main logic board terminal strip or I/O module outputs to

Start Source N Generator, and connect the engine start leads for the Source N generator set to the corresponding terminals on the terminal strip or I/O module terminals. See Sections 3.3.2 and 6.5.2. The programmed engine start output remains tied to the

Source N generator set regardless of the position of the preferred source switch.

The utility-utility mode is designed to use utility power for both Source N and Source E. This mode does not use the engine start outputs.

Time Delays and Source Parameters. Engine start relays and time delays, source voltage and frequency trip points, and load shed time delays are assigned to the source (N or E). They do not change assignment when the preferred source switch position is changed.

Note: Source N is always connected to the Normal side of the transfer switch, and Source E is always connected to the Emergency side.

Other time delays are assigned to the source function

(preferred or standby). System parameters that are assigned to the function automatically change source when the preferred source selection changes.

Figure 6-3 shows which parameters are assigned to the source and which are assigned to the function. The last two columns of the table show the effect of the preferred source selector switch position on each parameter or time delay.

42 Section 6 Accessories TP-6126 8/02

Item

Source N generator engine start relay

Source E generator engine start relay

Source N engine start time delay

Source E engine start time delay

Source N engine cooldown time delay

Source E engine cooldown time delay

Source N voltage and frequency trip points

Source E voltage and frequency trip points

Source N load shed time delays

Source E load shed time delays

In-phase monitor synch

Preferred-to-standby time delay

Standby-to-preferred time delay


Pretransfer to preferred signal

Pretransfer to standby signal

Post-transfer to preferred signal

Post-transfer to standby signal

Off-to-standby time delay (programmed-transition only)

Off-to-preferred time delay (programmed-transition only)

Assignment

Source

Source

Source

Source

Source

Source

Source

Source

Source

Source

Source

Function

Function

Function

Function

Function

Function

Function

Function

Function

Figure 6-3 Preferred Source Selection Effect on System Parameters and Time Delays

Preferred Source Switch Position

N E

N N

E

N

E

N

E

E

N

E

N

E

N to E

E to N

E

N

E

N

E

N

E

E

N

E

Off to E

Off to N

N

E

N

E

E

E to N

N to E

N

E

N

E

N

Off to N

Off to E


6.3.2

Supervised Transfer Control

Switch

The supervised transfer

(AUTO/MANUAL/TRANSFER control switch) is switch a three-position, key-operated switch that allows manual control of load transfers. The switch has maintained

AUTO and MANUAL positions and a momentary

TRANSFER position. The key can be removed in either the AUTO or MANUAL position. The key cannot be removed when the switch is in the TRANSFER position.

Figure 6-4 shows the switch.

The manual mode allows the system to run on the standby source indefinitely, even if the preferred source is available. In manual mode, the controller is inhibited from initiating a transfer sequence until the keyswitch is turned to the TRANSFER position.

It is not necessary to hold the switch in the TRANSFER position during the transfer sequence. Turn the switch to TRANSFER and release it to initiate transfer. The transfer sequence will proceed after the switch returns to the MANUAL position, executing all programmed time delays and transferring the load to the other source if it is available.

Automatic and Non-Automatic Transfer Switches.

The switch operation differs for automatic and non-automatic switches. An automatic transfer switch transfers automatically to an available source if the connected source is lost.

A non-automatic transfer switch does not transfer automatically, even if the connected source is lost. Figure 6-5 summarizes the switch operation.

Note: Transfer switches are built and UL-labeled as automatic or non-automatic by the factory and cannot be converted in the field. The supervised transfer control switch cannot be removed from non-automatic switches in the field.

Test and Peak Shave Operation.

When the supervised transfer control switch on an automatic system is in the MANUAL position, pressing the Test button or sending a peak shave command causes transfer to the standby source. However, ending the test or removing the peak shave signal will not cause a transfer back to the preferred source.

Move the supervised transfer control switch to the TRANSFER position to initiate transfer back to the preferred source.

Test and peak shave signals are ignored by non-automatic systems when the supervised transfer control switch is in the MANUAL position.

GM21286

Figure 6-4 Supervised Transfer Control Switch

Switch

Position

AUTO

MANUAL

TRANSFER

Operation, Automatic Switches Operation, Non-Automatic Switches

D Automatically transfers to the standby source, when available, if the preferred source is lost

D Transfers back to the preferred source when it becomes available

D Automatically transfers to an available source if the connected source is lost

D Does not automatically transfer back to preferred when both sources are available

D Enables the Not-in-Auto indicator

D Transfers only when the switch is manually moved to the TRANSFER position:

D Does not automatically transfer to an available source when the connected source is lost

D Does not automatically transfer back to preferred when both sources are available

D Can use to transfer when the switch is in the

MANUAL position and both sources are available

D Initiates transfer sequence to the other source, if available, including all programmed time delays

D Operates pre- and post-transfer load control time delays if both sources are available

D Must use for all transfers when the switch is in the

MANUAL position

D Initiates transfer sequence to the other source, if available, including all programmed time delays

D Operates pre- and post-transfer load control time delays if both sources are available

Figure 6-5 Supervised Transfer Control Switch Operation


6.4 In-Phase Monitor

Transfer switches are shipped with the in-phase monitor disabled. The factory settings are shown in Figure 6-6.

Use the Setup Program to enable the in-phase monitor and adjust the settings, if necessary. Refer to the Setup

Program Operation Manual.

Note: The in-phase monitor is not available on programmed transition switches.

The in-phase monitor operates when both sources are available, such as when transfering from the standby back to the preferred source. The in-phase monitor assures that transfer occurs when the two sources are in phase. The phase angle measuring accuracy is

±5_.

The in-phase monitor does not operate when one source is lost.

The OFF position LED on the user interface panel flashes at 2 Hz when the in-phase monitor is operating.

Synchronization Output. The synchronization output provides a contact closure that can be used to signal some generator set controllers to synchronize the two sources by adjusting the engine speed of a generator set equipped with a variable-speed governor. See the generator set operation manual. The system activates the output after the synch output time delay.

See

Figure 6-6.

Parameter

Enable/disable

Phase angle, degrees

Synch output time delay, seconds

Factory setting

Disable

0

30

Figure 6-6 In-Phase Monitor Factory Settings

6.5 Programmable Inputs and

Outputs

Programmable inputs and outputs are available through the controller main logic board terminal strip and through optional input/output (I/O) modules.

Programmable monitoring, control, and fault detection outputs are available through the terminal strip on the controller or through the programmable input/output

(I/O) modules.

The main logic board inputs and outputs are factory-assigned to the functions listed in Section 3.3.2.

The I/O modules are shipped with the input and output assignments undefined. The Setup Program is required to change the main logic board terminal strip input and output assignments and also to set up and assign inputs and outputs to the optional I/O modules. The table in

Figure 6-7 lists the available inputs. Figure 6-8 lists the available programmable outputs.

Programmable Inputs

Low External Battery Fault

Peak Shave/Area Protection

Inhibit Transfer

Remote Bypass Time Delay

Remote Test

Forced Transfer to OFF (programmed-transition models only; requires load shed accessory)

Remote Common Fault

Figure 6-7 Programmable Inputs


Programmable Output

Preferred Source Available

Standby Source Available

Contactor in Preferred Position

Contactor in Standby Position

Contactor in OFF position

Contactor in Source N Position

Contactor in Source E Position

Not in Auto

Load Control Active

Exerciser Active

Low Battery on Standby Source

Test Active

Peak Shave Active

Non-Emergency Transfer

Load Bank Control

Start Source N Generator

Start Source E Generator

Load Shed Disconnect 0--8

Synchronization Output Command

Common Alarm

Undervoltage Source N

Overvoltage Source N

Loss of Phase Source N

Phase Rotation Error Source N

Overfrequency Source N

Underfrequency Source N

Undervoltage Source E

Overvoltage Source E

Loss of Phase Source E

Phase Rotation Error Source E

Overfrequency Source E

Underfrequency Source E

Failure to Transfer

Auxiliary Switch Fault

Auxiliary Switch Open

Failure to Acquire Standby Source

I/O Module Lost

I/O Module Not Found

I/O Module Not Installed

Modbus r-Controlled Relay Driver

Output #1


Output #2


Output #3


Output #4

Control

Control

Control

Figure 6-8 Available Programmable Outputs

Fault

Fault

Fault

Fault

Fault

Fault

Fault

Fault

Fault

Fault

Fault

Control

Control

Fault

Fault

Fault

Fault

Fault

Fault

Fault

Fault

Fault

Monitor

Monitor

Monitor

Monitor

Monitor

Monitor

Control

Control

Control

Control

Type

Monitor

Monitor

Monitor

Monitor

Monitor

Monitor

Monitor

Monitor

46 Section 6 Accessories

6.5.1

Programmable Input/Output (I/O)

Modules

Programmable Input/Output (I/O) modules provide two inputs and six outputs, numbered 1--6, for controller communications. Up to four modules can be connected to the controller.

The I/O modules are mounted on a DIN rail and covered by a protective cover. See Figure 6-9. Figure 6-10 and

Figure 6-11 show typical I/O module locations.

1

2

3

4

GM21360

Figure 6-9 Input/Output Modules and Harness

(cover is shown transparent to show detail)

TP-6126 8/02

1

GM21360

1. I/O modules

Figure 6-10 Typical I/O Module Locations (welded enclosures)

1 1

6.5.2

I/O Module Connection

Optional input/output (I/O) modules are connected to the controller by a factory-installed harness.

Figure 6-12 shows the controller connection.

The input and output ratings are shown in Figure 6-13.

Figure 6-14 shows an I/O module with its input and output terminal blocks and address DIP switches.

Each I/O Module requires a unique address.

Factory-installed I/O module addresses are set at the factory.

1

2

Side View

Front View gm21360b

1. I/O module locations (typ.)

Figure 6-11 Typical I/O Module Locations (framework enclosures)

GM21079-A

1. I/O module harness GM21341

2. Transfer switch controller

Figure 6-12 I/O Circuit Board Module Harness

Connection to Transfer Switch Controller

I/O Module Item

Input

Output

Rating

16 mA@12 VDC

2 A@250 VAC

Figure 6-13 I/O Module Ratings


4

IN1--

IN1+

1

IN2--

IN2+

2

3 gm21115a

1. Controller harness connection

2. Address DIP switches

3. Input connections

4. Output connections

Figure 6-14 I/O Module Input and Output

Connections

I/O Module Connection Procedure

1. Disconnect power to the transfer switch before connecting to the I/O modules.

2. Remove the I/O module cover and connect devices to the I/O module input terminals on terminal block

TB1 or output terminals on terminal block TB2. See

Figure 6-14 for the terminla block locations. The output connections on the I/O module are labelled

RDO (relay driver output) 1 through 6. Use wire sizes within the specifications in Figure 6-15 for the input and output connections.

3. Tighten the connections to 0.5 Nm (4.4 in. lb.).

4. Record the connections on the label on the cover and replace the cover.

5. Use the Setup Program to set up the I/O board communications and to define the I/O board inputs and outputs.

Refer to the Setup Program

Operation Manual for instructions.

Component

Controller terminal strip I/O terminals

Number of Wires

1

Wire Size

Range

#12--24 AWG

I/O board terminals 1 #14--26 AWG

Figure 6-15 Input and Output Connection

Specifications

Tightening

Torque

0.5 Nm

6.5.3

I/O Module Address

Each I/O Module requires a unique address.

Factory-installed I/O module addresses are set at the factory.

To check the I/O module addresses, compare the DIP switch settings with Figure 6-16, starting with the module connected to the controller harness.

Figure 6-14 shows the address DIP switch location on the I/O module. Push down the end of the DIP switch near the OPEN label to open the switch, or push down the other end to close it. See Figure 6-17.

Number

1

2

3

4

1

Closed

Closed

Address DIP Switches

2 3

Closed

Closed

Closed

Open

Closed

Closed

Open

Open

Closed

Open

Figure 6-16 I/O Module Address DIP Switches

1 2 3

OPEN

1

1. Push this side down to open.

Figure 6-17 I/O Module Address DIP Switches

6126

6.5.4

I/O Module Faults and Diagnostics

When power is applied to the system, the controller attempts to initiate communication with each connected

I/O board. The following faults may occur on powerup if the I/O modules are not correctly installed, addressed, or configured in the setup software. Check the LED on each I/O module for diagnostic information in the case of a fault.

Diagnostic LED. Each I/O module has a diagnostic

LED that lights or flashes to indicate the I/O board status as described in the table in Figure 6-18.

I/O Module Not Found. If the system does not detect an I/O module at an expected address, the Service

Required LED flashes and the software logs the message, “I/O Module Not Found”.

Check that the number of I/O modules installed matches the number expected by the setup program. Check that the I/O


modules are connected and the address DIP switches are set correctly. Check the diagnostic LED to verify that the module is receiving power and communicating with the controller.

I/O Module Not Installed. If the software detects an I/O module that is connected but not expected by the setup program, the Service Required LED flashes and the software logs the message, “I/O Module Not Installed.”

The system ignores the board if it does not find the setup definition.

Check that the number of I/O modules expected in the Setup Program matches the number of modules installed on the transfer switch. Check that the

I/O module address DIP switches are set correctly.

Check the diagnostic LED.

I/O Module Communications Lost. If communication to an I/O module that was previously installed and working is lost, the Service Required LED flashes and the software logs the message “I/O Module

Communications Lost.” Check the I/O module connections and diagnostic LED.

I/O board

Status

Unpowered

Operating correctly

Power but no communication with control board

No defined program at I/O module address

Off

Diagnostic

LED

On, Steady

Quick Flash

(2 Hz)

Slow Flash

(0.5 Hz)

Figure 6-18 I/O Module Diagnostic LED

6.6 Load Shed (Forced Transfer to

OFF)

6.6.1

Description

The load shed (forced transfer to off) accessory allows the removal of non-critical loads from the Source E generator set.

The accessory requires an external signal (contact closure) to initiate transfer to the Off position.

The load shed (forced transfer to off) accessory is available only for programmed-transition transfer switches.

When the forced transfer to off input is activated (contact closed), the contactor moves from Source E to the OFF position immediately, ignoring all time delays. If the normal source is available when the input is activated, the ATS transfers to the Off position and then to Source

N, executing all programmed time delays. If Source N is not available, the ATS remains in the Off position until the input is deactivated. When the input is deactivated, the ATS transfers back to Source N, if available, executing all programmed time delays. If Source N is not available, the ATS transfers to Source E.

The load shed (forced transfer to off) function only sheds loads connected to Source E. The preferred source selector switch position (if equipped) does not affect this function.

6.6.2

Connection

On transfer switches with the factory-installed load shed accessory, the forced transfer to off input is assigned to main logic board terminal strip programmable input #2

(terminals 8 and 9). Connect the forced transfer to off signal from the generator set controller or other customer device to terminals 8 and 9 following the instructions in Section 3.3.2. Use #12--24 AWG wire and tighten the terminals to 0.5 Nm (4.4 in. lb.).

6.7 Security Cover

The gasketed, hinged security cover prevents unauthorized access to the transfer switch controls and protects the user interface from harsh environmental conditions. Use a customer-supplied padlock to lock the cover.

The cover is available with or without a window for

NEMA 1 enclosures. NEMA 3R enclosures include a windowless cover as standard equipment.


6.8 Battery Charger

The GM22502 is a 3-stage electronic battery charger designed for 12 or 24 VDC systems. It is designed to be used for lead acid batteries (flooded cell or AGM types) and gel cell batteries. The sealed and potted design is rainproof, lightweight, silent, and completely automatic.

The charger contains internal, self-resetting short-circuit protection for the outputs and fuses for reversed-polarity protection.

The battery charger produces 12 VDC at 6 Amps or

24 VDC at 3 Amps. Red and green LEDs indicate that the unit is recharging or maintaining the battery.

Figure 6-19 shows the battery charger. Refer to the transfer switch dimension drawing for the location of the battery charger.

WARNING

Sulfuric acid in batteries.


Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

WARNING

Explosion.


Relays in the battery charger cause arcs or sparks.

Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup.

Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

Battery gases.

Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire.

To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging.

Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles.


Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.


47.6

33.3

REF

REF

FUSE HOLDER (2)

AGC--10 10A

FASTBLOW FUSE

9.5

+

--

+

--

#10--32 TERMINALS TYP. (4)

234.4

215.9

RED LIGHT

GREEN LIGHT

7.1

(4)

6” LEAD LENGTH REF

(CHARGER BODY TO INSERTION END OF CONNECTOR)

GM22502-A

Figure 6-19 Battery Charger

6.8.1

Battery Charger Connection

The battery charger is powered by the load side of the transfer switch contactor through a factory-installed wiring harness with a 9-pin inline connector. Verify that the power to the ATS is disconnected before connecting or disconnecting the 9-pin connector to the battery charger.

Ring terminals for battery charger connections are included with the battery charger.

The installing technician must supply the cable with terminals between the battery charger and the battery.

Figure 6-21 provides details regarding cable length and gauge. Using red cable for battery positive (+) and black cable for battery negative (--) is strongly recommended.

Use the following procedure to connect the battery charger.

TP-6126 8/02

TERMINAL

INSERTION

END

PIN

1

2

5

6

3

4

7

8

9

CONNECTOR PIN--OUT

WIRE FUNCTION

1

2

NEUTRAL INPUT

208 VAC INPUT

--

4

--

3

6

--

5

--

240 VAC INPUT

--

480 VAC INPUT

EARTH GROUND

--

600 VAC INPUT

Figure 6-20 Battery Charger Power Connection

GM22502

Section 6 Accessories 51

Battery Charger Connection Procedure

DANGER

Hazardous voltage.



Connecting the battery and the battery charger.

Hazardous voltage can cause severe injury or death.

Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).

Have a qualified electrician install the battery(ies).

1. Verify that power to the ATS is disconnected

(switches or circuit breakers to the ATS are open).

2. Verify that the inline connector to the charger is disconnected.

3. Clean the battery terminals and check the battery according to the battery manufacturer’s instructions.

4. Determine the length of cable needed to connect the battery to the battery charger and refer to

Figure 6-21 for the required wire size.

The distances shown are the one-way distances from the charger to the battery.

Note: Use the recommended wire size to prevent overcharging the battery. Route AC and DC wiring in separate conduits.

5. Remove the boots and ring terminals from the battery charger posts.

Maximum

Distance

Wire Size

Battery Charger

Terminal Size

4.5 m (15 ft.) 12 AWG

7.5 m (25 ft.) 10 AWG

Figure 6-21 Battery Cable and Terminal

Specifications

Eyelet Terminal

Part No.

6. Slide a red boot onto the red cable and a black boot onto the black cable. Attach ring terminals and use a crimping tool to crimp the ring terminals tightly.

7. Determine whether the generator set electrical system uses 12 or 24 volts. This information is shown on the generator set nameplate.

8. Connect the jumpers as shown in Figure 6-22 for a12-volt system or Figure 6-23 for a 24-volt system, reconnecting the jumper lead for 24-volt systems as shown. Place the jumper lead terminal between the two flat washers on the battery charger terminal.

Note: Battery chargers are configured for 12-volt systems at the factory. For 24-volt systems, reconnect the jumper lead as shown in

Figure 6-23 and discard the second jumper lead.

9. Connect the battery cables as shown in

Figure 6-22 for 12 VDC systems or Figure 6-23 for

24 VDC systems.

Note: The positive (POS, P, +) battery post usually has a larger diameter than the negative

(NEG, N, --) post.

a. Connect the red POSITIVE terminal of the battery charger to the positive post of the battery.

b. Connect the black NEGATIVE terminal of the battery charger to the negative post of the battery.

10. Slide the boots over the battery charger posts.

11. Connect the in-line connectors on the battery charger power cord.


Battery Charger Disconnection Procedure

DANGER

+ --

+

--

6126

Figure 6-22 12-Volt Battery Charger Connections

Hazardous voltage.



1. Before opening the transfer switch enclosure, disconnect power to the transfer switch by opening switches or circuit breakers to the transfer switch.

2. Disconnect the AC power cord at the in-line connector.

3. Remove the black (NEGATIVE) wire from the the battery terminal first.

4. Remove the red (POSITIVE) wire from the battery terminal.

+ -+ --

6126

Figure 6-23 24-Volt Battery Charger Connections

12. Connect the charger to the battery according to the generator set or battery manufacturer’s instructions, watching the polarity (+/--) of the connections.

13. Close the enclosure door and reconnect power to the transfer switch after the charger connections are complete.

14. Use a voltmeter to check the voltage at the battery and compare the readings to Figure 6-25 or

Figure 6-26 to verify charger operation.


6.8.2

Battery Charger Operation

Red and green LEDs on the charger indicate the charge rate. Refer to Figure 6-24 for a description of the LED

On

LED Indicators

Red Green

Off

On On indicator operation. Figure 6-25 and Figure 6-26 show the 3-stage charging charging method for 12 VDC and

24 VDC configurations.

Operating Condition

The battery is discharged and the charger is recharging at the BULK rate (stage 1). This charging rate is 6 Amps at 12V or 3 Amps at 24V. The measured voltage (with the charger on) is 11.8 to 14

Volts in 12VDC mode or 23.6 to 28VDC 24VDC mode.

If the red LED stays on for more than 24 hours, refer to Problem 1 in the troubleshooting section in this manual.

The charger is charging at an ABSORPTION rate of between 1.5 and 5 Amps (stage 2). This mode of charging gradually “tops off” your battery, and reduces harmful sulfating. While both LED’s are on, the voltage measured (with the charger on) should be approx. 14.0 to 14.5VDC in 12VDC mode or 28.0 to 29.0 in 24VDC mode.

Off On

If both LED’s stay on longer than 24 hours, refer to Problem 2 in the troubleshooting section in this manual.

The charer is charging at a FLOAT or MAINTENANCE rate of less than 1.5 Amps, (stage 3). The battery is now 90% charged and ready for use. This ”float” charging current will gradually decrease to as low as 0.1 Amps as the battery reaches 100% charge. The float rate maintains the battery at full charge without overcharging.

If the green LED stays on when your battery is known to be low, refer to Problem 3 in the troubleshooting section in this manual.

Figure 6-24 Charger Operation

15

14

13

12

Bulk

(Red LED On)

11

6 5.5

5 4.5

Absorption

(Red/Green LEDs On)

Float

(Green LED On)

4 3.5

3

DC Amps

2.5

2 1.5

1 0.5

0.1

Figure 6-25 Charging Method, 12 VDC, 6 A Configuration gi267712


30

28

26

24

22

Bulk Absorption

(Red/Green LEDs On)

Float

(Green LED On)

20

3 2.5

2 1.5

DC Amps

Figure 6-26 Charging Method, 24 VDC 3 A Configuration

1 0.5

0.1

gi267712

6.8.3

Battery Charger Troubleshooting

Problem

Red LED stays on for more than 24 hours.

The red and green LEDs hours.

Green LED stays on known to be low.

Neither of the LEDs turn applied.

Cause

One or more defective or damaged cells.

Charger has reduced its output voltage below the normal level due to a DC overload or a DC short.

Solution

Load test the battery and replace if necessary.

Remove the source of the overload or short.

Disconnect the charger’s black (NEGATIVE) ring terminal from the battery. Reapply AC power and the green LED only should now light.

Turn off excessive DC equipment while charging.

On-board DC systems are drawing more current than the charger can replace.

On-board DC systems are drawing between 1.5 – 5A.


Extremely low AC voltage at the battery charger.

Open DC output fuse.

Turn off excessive DC equipment while charging.


Apply a higher AC voltage source or reduce the length of the power cord.

Replace the DC output fuse with a Bussmann

AGC--10.

Clean and tighten or repair all terminal connections.

Faulty or contaminated terminal connections.



No AC power available at the charger.

Connect AC power or reset the AC breaker on the main panel.

Component failure.

Return charger to the Service Department.

Figure 6-27 Battery Charger Troubleshooting


6.8.4

Battery Charger Specifications

Figure 6-28 lists the battery charger specifications.

Output

Charging 12 Volts DC (min.) at 6 Amps

24 Volts DC (min.) at 3 Amps

13.30 Volts DC at 0.1 Amps Maintaining

Input

Rated AC Voltage 208 VAC, AC connector pin 2

240 VAC, AC connector pin 4

480 VAC, AC connector pin 6

600VAC, AC connector pin 9

@ 50/ 60 Hz, 0.7 Amps Maximum Current Draw

Maximum Recommended Battery Size

Recharging 150 Amp--Hours

Maintenance only

Physical Dimensions

300 Amp--Hours

Height

Width

3.5 in. (8.9 cm.)

6.4 in. (16.3 cm.)

Depth

Weight

2.1 in. (5.3 cm.)

3.5 lb. (1.6 kg)

Figure 6-28 Battery Charger Specifications


Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere

ABDC after bottom dead center

AC

A/D alternating current analog to digital

ADC adj.

ADV

AHWT analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature

AISI

ALOP alt.

Al

ANSI

American Iron and Steel Institute anticipatory low oil pressure alternator aluminum

American National Standards Institute

(formerly American Standards Association, ASA)

AO

API anticipatory only

American Petroleum Institute approx.

approximate, approximately

AR as required, as requested

AS

ASE

ASME assy.

ASTM as supplied, as stated, as suggested

American Society of Engineers

American Society of Mechanical Engineers assembly

American Society for Testing Materials

ATDC

ATS auto.

aux.

A/V avg.

AVR

AWG after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator

American Wire Gauge

AWM bat.

BBDC

BC

BCA

BCI appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator

Battery Council International

BDC

BHP before dead center brake horsepower blk.

black (paint color), block (engine) blk. htr.

block heater

CARB

CB cc

CCA ccw.

CEC cfh cfm

BMEP bps br.

BTDC brake mean effective pressure bits per second brass before top dead center

Btu British thermal unit

Btu/min.

British thermal units per minute

C cal.

Celsius, centigrade calorie

California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise

Canadian Electrical Code cubic feet per hour cubic feet per minute

CG

CID

CL cm

CMOS cogen.

COM conn.

center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogeneration communications (port) connection cont.

CPVC crit.

CRT

CSA

CT

Cu cu. in.

cw.

CWC cyl.

D/A

DAC dB dBA

DC

DCR deg.,

° dept.

dia.

DI/EO

DIN continued chlorinated polyvinyl chloride critical cathode ray tube

Canadian Standards Association current transformer copper cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter decibel decibel (A weighted) direct current direct current resistance degree department diameter dual inlet/end outlet

Deutsches Institut fur Normung e. V.

(also Deutsche Industrie Normenausschuss)

DIP

DPDT

DPST

DS dual inline package double-pole, double-throw double-pole, single-throw disconnect switch

DVR digital voltage regulator

E, emer.

emergency (power source)

EDI

EFR electronic data interchange emergency frequency relay e.g.

EG

EGSA

EIA

EI/EO

EMI emiss.

eng.

EPA

EPS for example (exempli gratia) electronic governor

Electrical Generating Systems Association

Electronic Industries Association end inlet/end outlet electromagnetic interference emission engine

Environmental Protection Agency emergency power system

ER

ES

ESD est.

emergency relay engineering special, engineered special electrostatic discharge estimated

E-Stop emergency stop etc.

et cetera (and so forth) exh.

ext.

exhaust external

F fglass.

FHM fl. oz.

flex.

freq.

FS ft.

Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet ft. lbs.

foot pounds (torque) ft./min.

feet per minute g ga.

gram gauge (meters, wire size) gal.

gen.

genset

GFI gallon generator generator set ground fault interrupter

TP-6126 8/02 Appendix A-57

HC

HCHT

HD

HET hex

Hg

HH

HHC

GND, gov.

gph gpm ground governor gallons per hour gallons per minute gr.

GRD grade, gross equipment ground gr. wt.

gross weight

H x W x D height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury (element) hex head hex head cap

HP hr.

HS hsg.

HVAC

HWT

Hz

IC

ID

IEC horsepower hour heat shrink housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) integrated circuit inside diameter, identification

International Electrotechnical Commission

IEEE

IMS

Institute of Electrical and Electronics Engineers improved motor starting in.

inch in. H

2 in. Hg

O inches of water inches of mercury in. lbs.

Inc.

ind.

int.

inch pounds incorporated industrial internal int./ext.

internal/external

I/O input/output

IP

ISO

J iron pipe

International Organization for Standardization joule

JIS k

K kA

Japanese Industry Standard kilo (1000) kelvin kiloampere kilobyte (2

10 bytes) KB kg kg/cm kgm kg/m

3 kHz kJ

2 kilogram kilograms per square centimeter kilogram-meter kilograms per cubic meter kilohertz kilojoule km kilometer kOhm, k

W kilo-ohm kPa kilopascal kph kV kVA kVAR kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kW kWh kWm

L kilowatt kilowatt-hour kilowatt mechanical liter

LAN local area network

L x W x H length by width by height lb.

lbm/ft

3

LCB pound, pounds pounds mass per cubic feet line circuit breaker

LCD liquid crystal display ld. shd.

load shed

LED light emitting diode

A-58 Appendix

Lph

Lpm

LOP

LP liters per hour liters per minute low oil pressure liquefied petroleum

LPG

LS liquefied petroleum gas left side

L wa

LWL

LWT sound power level, A weighted low water level low water temperature m

M m

3 m

3 meter, milli (1/1000) mega (10

6 cubic meter when used with SI units), male

/min.

cubic meters per minute mA man.

milliampere manual max.

MB maximum megabyte (2

20 bytes) one thousand circular mils MCM

MCCB molded-case circuit breaker meggar megohmmeter

MHz mi.

mil min.

megahertz mile one one-thousandth of an inch minimum, minute misc.

MJ mJ miscellaneous megajoule millijoule mm millimeter mOhm, m

W milliohm

MOhm, M

W megohm

MOV

MPa mpg mph metal oxide varistor megapascal miles per gallon miles per hour

MS m/sec.

MTBF

MTBO mtg.

military standard meters per second mean time between failure mean time between overhauls mounting

MW megawatt mW mF milliwatt microfarad

N, norm.

normal (power source)

NPS

NPSC

NPT

NPTF

NR ns

OC

OD

NA not available, not applicable nat. gas natural gas

NBS

NC

National Bureau of Standards normally closed

NEC

NEMA

NFPA

Nm

National Electrical Code

National Electrical Manufacturers Association

National Fire Protection Association newton meter

NO normally open no., nos.

number, numbers

National Pipe, Straight

National Pipe, Straight-coupling

National Standard taper pipe thread per general use

National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter

OEM

OF opt.

OS

OSHA

OV oz.

original equipment manufacturer overfrequency option, optional oversize, overspeed

Occupational Safety and Health Administration overvoltage ounce

TP-6126 8/02

p., pp.

PC

PCB pF page, pages personal computer printed circuit board picofarad

PF ph.,

PHC power factor

Æ phase

Phillips head crimptite (screw) rly.

rms rnd.

ROM rot.

rpm

RS

RTV rad.

RAM

RDO ref.

rem.

RFI

RH

RHM

SAE scfm

SCR s, sec.

SI psi pt.

PTC

PTO

PVC qt.

qty.

R

PHH

PHM

PLC

PMG pot ppm

PROM

SI/EO sil.

SN

Phillips hex head (screw) pan head machine (screw) programmable logic control permanent-magnet generator potentiometer, potential parts per million programmable read-only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement (emergency) power source radiator, radius random access memory relay driver output reference remote radio frequency interference round head round head machine (screw) relay root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization

Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second

Systeme international d’unites, International System of

Units side in/end out silencer serial number

UF

UHF

UL

UNC

UNF univ.

US

UV

V

VAC

VAR

VDC

VFD

VGA

VHF

W

WCR w/ w/o wt.

xfmr

TDEC

TDEN

TDES

TDNE

TDOE

TDON temp.

term.

TIF

TIR tol.

turbo.

typ.

SPDT

SPST single--pole, double--throw single--pole, single--throw spec, specs specification(s) sq.

sq. cm sq. in.

SS square square centimeter square inch stainless steel std.

stl.

tach.

TD

TDC standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency

Underwriter’s Laboratories, Inc.

unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer


Appendix B Specifications

Withstand and Closing Ratings, Open- and Programmed-Transition Models

Maximum current in RMS symmetrical amperes when coordinated with customer-supplied fuses or circuit breakers.

Any Circuit Breaker

Switch

Rating,

Amps

30

[

70

[

104

[

150

[

150 w

200

[

Cycles @

60 Hz

1.5

3

1.5

kAmps @

480 VAC

10

35

10

(240 VAC max.) kAmps @

600 VAC

10

22

N/A

S ifi Ci it

Breaker

Max. kAmps @

480 VAC

N/A kAmps

100

Current-Limiting Fuses

Volts,

Max.

Fuse Size,

Amps

60

Type

200

42

22

(240 VAC max.)

200 240

450

200

J

J

600

1000

1200

1600

]

2000

]

18 ** 36

50

36

200

L

* All values are available symmetrical RMS amperes and tested in accordance with the withstand and close-on requirements of UL 1008.

200 amp switches are limited to 240 VAC max., copper wire only. Application requirements may permit higher withstand ratings for certain size switches. Contact Kohler Co. for assistance.

[ Open-transition models only w Programmed-transition models only

] Optional front-connected service limited to 85,000 amps for specific and any breaker ratings.

** Withstand rating only. This testing is not defined in UL 1008.

A-60 Appendix TP-6126 8/02

Ratings with Specific Manufacturers’ Circuit Breakers

Open- and Programmed-Transition Models

The following charts list power switching device withstand and closing ratings (WCR) in RMS symmetrical amperes for specific manufacturers’ circuit breakers. Circuit breakers are supplied by the customer.

Molded-Case Circuit Breakers

Rating,

Amps

WCR, kA

RMS

Voltage,

Max.

Manufacturer

GE

ITE

Merlin Gerin

GE

ITE

ITE

Cutler-Hammer

ABB

Type

FH

FC, FI

KA, KC, KH, KI, LA, LH

TB1

TEL, THED, THLC1, THLC2

TFL

CED6, ED6, HED4, HED6

CFD6

FD6, FXD6, HFD6

FCL, Tri-Pac FB

FD, FDC, HFD

HJD, JD, JDB, JDC

HKD, KD, KDB, KDC, LCL, Tri-Pac LA

S1

S3

CE104, CE106

FC, FI

KA, KC, KH, KI, LA, LH

TB1

TEL, THED, THLC1, THLC2

TFL

CED6, ED6, HED4, HED6

CFD6

FD6, FXD6, HFD6

FCL, Tri-Pac FB

FD, FDC, HFD

HJD, JD, JDB, JDC

HKD, KD, KDB, KDC, LCL, Tri-Pac LA

S1

S3

CE104, CE106

CF250

TEL, THED, THLC1

TFL, THFK, THLC2

SFL, SFP, TFJ, TFK

SGL4, SGP4, TLB4

CFD6, FD6, FXD6, HFD6

CJD6, HHJD6, HHJXD6, HJD6, JD6, JXD6, SCJD6, SHJD6,

SJD6

KA, KC, KH, KI

LC, LI

LA, LH

FD, FDC, HFD

HJD, JD, JDB, JDC

LCL, Tri-Pac LA, HKD, KD, KDB, KDC

S3

CF250

CJ400

400

250

300

400

150

250

400

150

250

400

225

125

150

250

100

150

250

125

150

100

100

250

100

150

Max. Size,

Amps

80

100

250

100

150

225

125

150

250

100

150

250

400

400

125

150

100

250

150

225

250

400

250

* Open-transition models only

[ Programmed-transition models only


Ratings with Specific Manufacturers’ Circuit Breakers, continued


Rating,

Amps

WCR, kA

RMS

Voltage,

Max.

Manufacturer

150

[

42 480

GE

ITE

ABB

GE

ITE

GE

Type

TEL, THED, THLC1,

TFL, THLC2

SFL, SFLA, SFP

SGL4, SGP4, TB4, THLC4, TLB4

SGLA, SGL6, SGP6, TB6

CFD6, HFD6

CJD6, HHJD6, HHJXD6, HJD6, SCJD6, SHJD6

CLD6, HHLD6, HHLXD6, HLD6, SHLD6

KC, KI

LC, LI

HJD, JDC

LCL, Tri-Pac LA, HKD, KDC

HLD

Tri-Pac NB

S3

CF250

CJ400

TFL, THFK, THLC2

SFL, SFP, TFJ, TFK

SGL4, SGP4, TLB4



SJD6

KA, KC, KH, KI

LC, LI

LA, LH

HJD, JD, JDB, JDC

LCL, Tri-Pac LA, HKD, KD, KDB, KDC

CF250

CJ400

TFL, THLC2

SFL, SFLA, SFP



SKHA, SKLB, SKP8, TKL



SJD6

CLD6, HHLD6, HHLXD6, HLD6, SCLD6, SHLD6

CMD6, HMD6, HND6, MD6, MXD6, SCMD6, SHMD6, SMD6,

SND6

KC, KI

LC, LI

MH

HJD, JDC

HKD, KDC, LCL, Tri-Pac LA

HLD

Tri-Pac NB

S5

S6

CF250

CJ400



400

400

225

250

400

600

800

250

250

300

400

250

400

250

Max. Size,

Amps

150

225

250

400

600

250

400

600

250

400

250

400

600

800

150

250

400

225

250

400

250

400

600

800

600

800

400

600

250

400

250

600

800

250

400


Ratings with Specific Manufacturers’ Circuit Breakers, continued


Rating,

Amps

WCR, kA

RMS

Voltage,

Max.

Manufacturer

600

65

600

GE

Cutler-Hammer

Merlin Gerin

Cutler-Hammer

Type



SKHA, SKL8, SKP8, TKL

CJD6, HHJD6, HHJXD6, HJD6, SCJD6, SHJD6

CLD6, HHJD6, HHLXD6, HLD6, SCLD6, SHLD6

CMD6, HMD6, HND6, MD6, MXD6, SCMD6, SHMD6, SMD6,

SND6

LC, LI

MH

HKD, KDC, LCL, Tri-Pac LA

HLD

Tri-Pac NB

S5

S6

CJ600

TB8

Microversatrip TKL

CLD6, HHLD6, HHLDX6, HLD6, SCLD6, SHLD6

CMD6, HMD6, SCMD6, SHMD6

CND6, HND6, SCND6, SHND6

CPD6

MH Series 2

SE (LS Trip), SEH (LS Trip)

Tri-Pac NB

Tri-Pac PB

RDC

S6

S7

CJ600

CK1200



Environmental Specifications

Operating

Temperature

Storage

Temperature

Humidity

Altitude

Environmental Specifications

--20

°C to 70°C (--4°F to 158°F)

--40

°C to 70°C (--40°F to 158°F)

5% to 95% noncondensing

0 to 3050 m (10000 ft.) without derating

Max. Size,

Amps

400

600

800

400

600

800

800

1200

1600

1000

2500

800

1600

2500

800

1200

600

1200

600

800

400

600

800

400

800

600

800

1200

600


Codes and Standards

The ATS meets or exceeds the requirements of the following specifications:

D

Underwriters Laboratories UL 508, Standard for

Industrial Control Equipment

D

Underwriters Laboratories UL 1008, Standard for

Automatic Transfer Switches

D

Underwriters Laboratories Inc., listed to Canadian

Safety Standards (cUL)

D

NFPA 70, National Electrical Code

D

NFPA 99, Essential Electrical Systems for Health

Care Facilities

D

NFPA 110, Emergency and Standby Power Systems

D

IEEE Standard 446, IEEE Recommended Practice for Emergency and Standby Power Systems for

Commercial and Industrial Applications

D

NEMA Standard IC10--1993 (formerly ICS2--447),

AC Automatic Transfer Switches

Diagrams and Drawings

Model

30--200A, Open-Transition






4000A, Open-Transition

150--400A, Programmed Transition





4000A, Programmed Transition

Schematic

GM20612

GM20613

GM20611

GM20611

GM20616

GM20619

GM20619

GM20616

GM20616

D

EN61000-4-5 Surge Immunity Class 4

(voltage sensing and programmable inputs only)

D

EN61000-4-4 Fast Transient Immunity

Severity Level 4

D

IEC Specifications for EMI/EMC Immunity:

D

CISPR 11, Radiated Emissions

D

IEC 1000-4-2, Electrostatic Discharge

D

IEC 1000-4-3, Radiated Electromagnetic Fields

D

IEC 1000-4-4, Electrical Fast Transients (Bursts)

D

IEC 1000-4-5, Surge Voltage

D

IEC 1000-4-6, Conducted RF Disturbances

D

IEC 1000-4-8, Magnetic Fields

D

IEC 1000-4-11, Voltage Variations and

Interruptions

Wiring Diagram

GM20602

GM20604

GM20605

GM20605

GM20606

GM20609

GM20609

GM20610

GM20610

Dimension Drawing

Enclosure Drawing Number

NEMA 1

ADV-6698

NEMA 12, 4, 4X

ADV-6699

NEMA 1

ADV-6700

NEMA 12, 4, 4X

NEMA 1

NEMA 12, 4, 4X

NEMA 1

NEMA 1

NEMA 1

Front-Connected

ADV-6701

ADV-6702

ADV-6702

ADV-6663

ADV-6664

ADV-6684

NEMA 1

NEMA 1

NEMA 1

NEMA 1

NEMA 12, 4, 4X

NEMA 1

NEMA 1

NEMA 1

Front-Connected

NEMA 1

NEMA 1

ADV-6665

ADV-6666

ADV-6704

ADV-6702

ADV-6703

ADV-6663

ADV-6664

ADV-6684

ADV-6665

ADV-6666


TP-6126 8/02b

E 2002 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044

Phone 920-565-3381, Fax 920-459-1646

For the nearest sales/service outlet in the

US and Canada, phone 1-800-544-2444

KohlerPowerSystems.com

Kohler Power Systems

Asia Pacific Headquarters

7 Jurong Pier Road

Singapore 619159

Phone (65)264-6422, Fax (65)264-6455

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